Spec. Standard: 03/24/10 11175-1 Revision: 02/15/12 SECTION 11175 PUMP STATION INTAKE DEBRIS REMOVAL SYSTEM PART 1 - GENERAL 1.01 SCOPE : A. Summary of Work: The CONTRACTOR shall furnish all labor, equipment and materials to provide and install a debris rack and debris removal system with all required appurtenances for cleaning vegetation and other debris from the rim canal located upstream of the pump station intake. The collection system shall be capable of being mounted directly to the proposed maintenance access bridge as shown on the Drawings. The acceptable debris removal system is generally described below. The debris removal system shall be a series of mechanical rake units which are capable of continuous operation and are dedicated to specific sections of the pump station intake debris rack system. Each rake unit shall be a chain driven, front-cleaning, front-return type designed to eliminate the necessity for underwater drive components. The system shall include all auxiliary equipment and accessories needed for a complete and fully functional debris removal system. Each unit shall be capable of operating independent of each other. Vegetation and debris collected from the rake units shall be conveyed and discharged to a belt conveyor which will convey the collected screenings to a dump pad or container for disposal. B. Related Work Specified Elsewhere: 1. SECTION 01670 Equipment Alignment 2. SECTION 09900 Protective Coatings 3. SECTION 16150 Motors 4. DIVISION 16 Electrical 1.02 REFERENCES : A. Standards or Codes: The edition of the publications of the organizations listed below in effect at the time of the advertisement for bids form a part of this specification to the extent referenced. See the various paragraphs for the specified standard. In the case of a conflict between the requirements of this Section and those of the listed document, the requirements of this Section shall prevail. 1. Anti-Friction Bearing Manufacturers Association (AFBMA) 2. American Welding Society (AWS) 3. American Society for Testing and Materials (ASTM) 4. National Electrical Manufacturer's Association (NEMA) 5. Steel Structures Painting Council (SSPC) 6. Florida Building Code (FBC) 7. American Institute of Steel Construction (AISC) 8. American National Standards Institute (ANSI) 9. Conveyor Equipment Manufacturers Association (CEMA) 10. National Fire Protection Association (NFPA) 1.03 SUBMITTALS : Submittal requirements are covered in SECTION 01300. Additional requirements are as follows: A. Manufacturer’s Qualifications: The CONTRACTOR will be required to request and submit to the DISTRICT appropriate documentation certifying that the Manufacturer fully complies with the requirements of paragraph 1.04.
SECTION 11175 PUMP STATION INTAKE DEBRIS REMOVAL SYSTEM
PART 1 - GENERAL
1.01 SCOPE:
A. Summary of Work: The CONTRACTOR shall furnish all labor, equipment and materials to provide and install a debris rack and debris removal system with all required appurtenances for cleaning vegetation and other debris from the rim canal located upstream of the pump station intake. The collection system shall be capable of being mounted directly to the proposed maintenance access bridge as shown on the Drawings. The acceptable debris removal system is generally described below.
The debris removal system shall be a series of mechanical rake units which are capable of continuous operation and are dedicated to specific sections of the pump station intake debris rack system. Each rake unit shall be a chain driven, front-cleaning, front-return type designed to eliminate the necessity for underwater drive components. The system shall include all auxiliary equipment and accessories needed for a complete and fully functional debris removal system. Each unit shall be capable of operating independent of each other. Vegetation and debris collected from the rake units shall be conveyed and discharged to a belt conveyor which will convey the collected screenings to a dump pad or container for disposal.
B. Related Work Specified Elsewhere: 1. SECTION 01670 Equipment Alignment 2. SECTION 09900 Protective Coatings 3. SECTION 16150 Motors 4. DIVISION 16 Electrical
1.02 REFERENCES:
A. Standards or Codes: The edition of the publications of the organizations listed below in effect at the time of the advertisement for bids form a part of this specification to the extent referenced. See the various paragraphs for the specified standard. In the case of a conflict between the requirements of this Section and those of the listed document, the requirements of this Section shall prevail. 1. Anti-Friction Bearing Manufacturers Association (AFBMA) 2. American Welding Society (AWS) 3. American Society for Testing and Materials (ASTM) 4. National Electrical Manufacturer's Association (NEMA) 5. Steel Structures Painting Council (SSPC) 6. Florida Building Code (FBC) 7. American Institute of Steel Construction (AISC) 8. American National Standards Institute (ANSI) 9. Conveyor Equipment Manufacturers Association (CEMA) 10. National Fire Protection Association (NFPA)
1.03 SUBMITTALS: Submittal requirements are covered in SECTION 01300. Additional requirements are as follows:
A. Manufacturer’s Qualifications: The CONTRACTOR will be required to request and submit to the DISTRICT appropriate documentation certifying that the Manufacturer fully complies with the requirements of paragraph 1.04.
B. Technical Data: Design calculations as well as layout and shop drawings which are dimensioned and scaled, with complete bill of material including part descriptions, part numbers, material specifications, electrical and control specifications, etc., shall be furnished for the following equipment:
a. Pump station intake debris rack b. Chain driven, front-cleaning, front-return type mechanical debris rake units c. Belt conveyor unit d. Ancillary equipment and components
At a minimum the technical data shall include the following: 1. Hydraulic design calculations including recommendations of the existing pump Manufacturer
regarding the maximum bar openings 2. Structural design calculations which clearly indicate the debris loading assumptions, rake
requirements, and hydraulic loading assumptions 3. Rake performance data including debris loading assumptions, system capacity, operating
speeds, lift capacity, etc. 4. Disposal facility requirements 5. Electrical and control system data and schematics 6. Structural design calculations and detailed drawings for all required modifications to the
existing pump station structure and/or the proposed maintenance access bridge
The shop drawings shall clearly indicate the size, type, material and tolerances for all mechanical and structural components and members. The shop drawings shall also indicate where the design deviates from the component sizes, types, materials and dimensions shown on the Drawings. Any proposed deviation from component sizes, types, materials and dimensions shown on the Drawings shall be approved, in writing, by the DISTRICT. All shop drawings and design calculations shall be signed and sealed by a licensed Florida Professional Engineer.
C. Manufacturer’s standard catalog data shall include a description and depiction of each component in sufficient detail to demonstrate full compliance with this specification. If standard catalog data does not contain sufficient detail to verify compliance, then CONTRACTOR shall submit supplementary documentation as required. All data submitted shall be on Manufacturer’s letterhead and signed by a company representative or official authorized to make technical representations of its company’s products.
D. Operation and Maintenance Manuals shall, at a minimum, include the following: 1. Installation instructions, including procedures for system startup and shutdown. 2. Component catalog information. 3. Service sheets for all system components. 4. Spare parts list of each equipment component, with a description of each item, Manufacturer,
catalog number, serial number and other information required to order an exact replacement. 5. Replacement parts data, including serial numbers.
E. Operational Field Test Report
F. Manufacturer’s Certification of Compliance with Specifications in accordance with paragraph 1.06.
G. Installation and Erection Manual
H. Manufacturer’s Certification of Equipment Installation in accordance with paragraph 3.05
I. Manufacturer’s Warranty: The CONTRACTOR shall submit documentation from the debris removal system Manufacturer indicating that the equipment warranty fully complies with the requirements of paragraph 1.08.
1.04 MANUFACTURER’S QUALIFICATIONS: The Manufacturer of the debris removal system shall have the following minimum qualifications to be considered an acceptable Manufacturer to provide, install, and service the equipment specified in this Contract:
A. Experience: The equipment Manufacturer supplying the design and fabrication services for the project shall have been in the business of designing and fabricating similar types of debris removal systems specified herein for a minimum of five (5) years (from the date of the submittal). The Manufacturer shall have completed a minimum of five (5) similar installations over that time period all of which are currently in service as constructed. The Manufacturer shall provide a minimum of five (5) references of projects that the Manufacturer has provided debris removal systems of equal or larger size. These project references shall include the name and telephone number of the owner’s representative who has direct knowledge of the performance of the Manufacturer. The reference must indicate an acceptable performance by the Manufacturer to be considered by this Contract.
B. Technical Support: The Manufacturer shall have an engineering service department to support the project design, perform the required tests, and provide field supervision of the installation.
C. Service: The Manufacturer shall have a service department capable of providing immediate response (24 hour notice), to service calls. The Manufacturer’s service department shall include skilled technicians and mechanics that can diagnose and repair the equipment supplied by this Contract.
1.05 PRODUCT QUALIFICATION: The rakes and conveyance equipment supplied shall be from a product line that has been used in similar applications and is backed with after-sales service from factory-direct engineering representatives. Spare parts shall be readily available and be “off-the-shelf” from the Manufacturer of the equipment. To facilitate this components for the equipment provided shall not be custom fabricated specifically for this project and shall be standard components used as part of the specific equipment product line.
1.06 MANUFACTURER’S CERTIFICATION: The CONTRACTOR shall submit a letter to the DISTRICT from the Manufacturer of the debris collection system, signed by an individual with authority to bind the company, and certifying that the Manufacturer has read and studied the Contract Documents and agrees to conform and comply with all of the requirements of this specification. All exceptions to the requirements of this specification, including those addressed by compliance submittals, shall be clearly stated in the certification letter. The CONTRACTOR is specifically advised that statement of exceptions does not relieve the Manufacturer from fully complying with the stipulated requirements in the project specifications unless approved, in writing, by the DISTRICT.
1.07 INSTALLATION AND ERECTION MANUAL: The CONTRACTOR shall submit, no later than at the time of delivery, the Installation and Erection Manual describing the procedures to be followed in erecting, assembling, installing, and testing the rake and conveyance equipment. The manual shall include such things as alignment procedures, bolt torque values, permissible clearances, permissible shaft misalignment, bearing clearances, etc.
1.08 WARRANTY:
A. The Manufacturer shall warrant the EQUIPMENT, MATERIALS and PRODUCTS specified in this Section against defective materials and workmanship with the Manufacturer’s standard warranty, but for no less than five years from the date of Substantial Completion, and as described in Article 13 of Section 00700 - General Terms and Conditions. If the Manufacturer’s standard warranty is less than the stipulated period, the Manufacturer shall provide a special Manufacturer’s extended warranty for the stipulated period.
B. The CONTRACTOR shall warranty the Work against defects for one year from the date of Substantial Completion and as described in Article 13 of Section 00700 - General Terms and Conditions.
A. General: Design, furnish and install custom engineered debris racks complete with all structural support and anchorage. The racks shall be supplied by the Manufacturer of the debris rake system to ensure complete compatibility. The racks shall at a minimum satisfy the following general requirements: 1. Rack Requirements: The racks shall be designed to protect the pump from damage in
accordance with the recommendations of the pump Manufacturer. The CONTRACTOR shall coordinate the design furnished by the debris rack Manufacturer with the requirements of the existing pumps to ensure the racks address all the recommendations of the pump Manufacturer. The clear spacing of the bars shall not be more than 3-inches. The maximum flow velocity through the racks shall be less than 2.5 fps when calculated at the design capacity (all pumps ON) flow of the pump station.
2. Head Loss: In accordance with US Army Corps of Engineers Engineering Manual EM1110-2-3105, “Mechanical and Electrical Design of Pumping Stations”, the design head loss through a clean debris rack should not exceed 6 inches at the pump station’s design capacity. In addition, the hydraulic design of the debris collection system shall assume a partially (50%) blocked rack with a maximum of one foot head loss across the debris rack at the pump station’s design capacity.
3. Debris racks shall be inclined 30-degrees from the vertical plane. 4. Debris Loading: The rack Manufacturer shall investigate the historical and field conditions to
develop a design debris loading rate for the collection system. 5. Service Life: The racks shall be designed to provide a minimum twenty five (25) year service
life under the service conditions described herein. 6. Removal and Reinstallation: The rack shall be capable of being removed to allow for
maintenance, refurbishment or replacement. Anchorage of the rack shall be at the service bridge with the toe of the rack resting on the sill plate as indicated on the Contract Drawings. The rack shall be designed for two lift points. The rack anchorage shall be readily accessible with adequate tolerance to facilitate easy reinstallation. All fasteners shall be equipped with a locking device such as a lock nut and locking washer.
B. Fabrication: The rack shall be rigid frame of all welded construction and consist of vertical parallel flat bars with regularly spaced horizontal cross braces for stability. The toe of the rack shall have a flat plate for added stiffness. All welding shall be in accordance with ANSI/AWS D1.6 and AWS D14.1 Specification for Welding of Industrial and Mill Cranes and Other Material Handling Equipment.
C. Structural Design: The structural design of all components shall be in accordance with the AISC Manual of Steel Construction and AWS 14.1. 1. Design Loads: The design shall address all live and dead loads with a minimum 25% increase
in live loads to address impact loads caused by the operation of the debris rake collection system. The rack shall be designed for a minimum hydrostatic loading corresponding to a five foot differential head across the screen where the low water elevation is equal to the pump’s low water shut off elevation. The force due to this head differential shall be applied across the full width of the rack. Each lifting lug shall be designed to withstand a load of no less than three times the dead weight of the rack.
2. Rack Deflection: The maximum allowable deflection of the rack shall be L/360. 3. Intermediate Support: A maximum of one intermediate support may be provided, if required.
All materials of the support shall be 304 stainless steel. The support member, if not an integral part of the rack, shall be easily removed and re-installed for pump maintenance.
4. Minimum Bar and Component Size: All structural members shall have a minimum thickness of 0.375 inches. The vertical collection bars shall have a minimum depth of 3.0 inches.
5. Allowable Stresses: Allowable stress for the rack’s structural elements shall not exceed those stated in AISC Manual of Steel Construction and shall also not be higher than the following percentages of the minimum yield strength of the materials used:
Tension (on net section at holes) ................................................................. 40% Bending (tension and compression on extreme fibers of members) ........... 55% Shear (on gross section of member) ............................................................ 35% Bearing on contact area of machine surfaces .............................................. 70%
Stress concentration factors shall be used where applicable.
D. Flow Induced Vibration: The rack shall be designed to prevent resonant vibrations induced by flow through the rack. The laterally unsupported lengths of the vertical bars and other members shall limit the natural frequency of the rack when submerged and subject to flow to not less than 2.5 times the vortex shedding frequency. Fixed supports shall be assumed for the calculation of the natural frequency of the rack. The average net flow velocity at the rack shall be increased 50% to account for flow concentration. The Strouhal’s number shall be NS = 0.14 + 0.01(d/t); d = bar depth, t =bar thickness.
E. Material Standards: The materials specified are considered to be the minimum acceptable materials for the purposes of durability, strength and resistance to erosion and corrosion. The CONTRACTOR, at his option, may elect to propose alternative material(s) for the purpose of providing greater strength or to meet required stress limitations and/or to provide additional corrosion resistance. The CONTRACTOR is specifically advised however that all proposed alternative materials will be considered as substitutes and therefore shall be submitted in accordance with the DISTRICT’s product substitution process and SECTION 01630. The DISTRICT reserves the right to deny any and all product substitutions requests. The CONTRACTOR will not be provided with additional compensation to offset any additional costs to provide the specified materials below in the event that a product substitution is not approved. In general, alternative materials must provide at least the same qualities as those specified for the purpose. Regardless, all materials shall conform to the latest ASTM specification or other listed commercial specifications covering the class or kind of material to be used.
ITEM MATERIAL Bars, plates or other structural shapes Stainless steel - ASTM A276 type 304 Nuts, Bolts, Anchors, Fasteners Stainless steel - ASTM F593 type 316 (bolts) Stainless steel - ASTM F594 type 316 (nuts)
F. Member Sizing: The CONTRACTOR is specifically advised that where structural member sizes have been indicated, the member sizes shall be considered to be the minimum acceptable. The CONTRACTOR shall be solely responsible for ensuring that all members are properly sized for the intended application.
G. Submittals: Submit for approval the following compliance submittals in accordance with PART 1: 1. Detailed fabrication and layout drawings including materials of construction 2. Hydraulic design values and calculations 3. Recommendation from the existing pump Manufacturer regarding the maximum bar
clearances to mitigate the potential for pump damage. 4. Structural design including debris loading values, rake requirements, and hydraulic loading
values 5. Detailed drawings for any required modifications to the intake structure, service bridge and/or
intake channel.
2.02 DEBRIS RAKE AND CONVEYANCE EQUIPMENT – GENERAL REQUIREMENTS:
A. Design, furnish and install an engineered debris rake and conveyance system complete with all mechanical and structural components, supports, motors, and monitoring and control components. The rake and conveyance equipment shall remove debris accumulated on the debris rack and convey
it to disposal area(s) as shown on the Contract Drawings. The debris rake and conveyance equipment shall be suitable for outdoor service. The selected equipment shall satisfy the following general requirements: 1. Head Loss: The cycle time of the proposed debris rake system shall prevent a build-up of
debris on the rack that will cause a head loss in excess of one foot across the rack at the pump station design capacity, for an assumed extreme loading event.
2. Debris Loading: Under normal operation the debris will consist of floating and submerged aquatic and wetland vegetation. This vegetation may vary from tall grasses, reeds and other aquatic plants such as hydrilla, to floating leafy plants such as water hyacinth. The rate of loading will vary seasonally as well as with discharge conditions. During a flood event there is the possibility of larger objects and materials included with the debris load. This debris could be upland vegetation, including small trees and brush, as well as man-made items such as lumber, tires, containers, etc. It is recommended that representatives from the rake Manufacturer visit the project site to evaluate the service condition requirements and determine the adequacy of the proposed debris rake and conveyance equipment.
a. Handling Capacity: The rake and its conveyance equipment shall be capable of collecting and conveying the debris described above in a cycle time that will result in a head loss across the rack less than the maximum allowed. Because of the debris loading rate variability, the cycle time shall be capable of adjustment to optimize the rake’s performance. The maximum debris volume (loose) shall be assumed to be 0.1% of the pump station design capacity. The density of the collected debris screenings shall be assumed to be 35 pounds per cubic foot (pcf) dry and 65 pcf wet. The minimum lift capacity for each rake mechanism supplied and installed shall be 1,000 lbs.
b. A summary of the pump station design information is provided below.
Pump Station Number S-133 S-135
Overall Intake Rim Canal Width, ft. 175 250
Rated Capacity of Pump Station / Largest Pump at Station, cfs 625 / 125 500 / 125
Minimum Rake Lift Capacity, lbs. 1,000 1,000
Intake Bay Width, ft. 56.0 45.5
Maximum Bar Spacing, inches 3-inches 3-inches
Service Bridge Deck Elevation (NGVD29), ft. 21.0 21.0
Channel Invert Elevation, ft. 1.5 1.5
Maximum Water Surface Elevation, Upstream, ft. 15.0 15.0
Minimum Water Surface Elevation, Downstream, ft. 13.0 13.0
Maximum Head Differential Across the Debris Rack at Peak Flow, 50% blocked, ft. 1.0 1.0
3. Service Life: The debris rake and conveyance equipment shall be designed to provide a
minimum twenty-five (25) years of reliable service under the loading conditions and operation described herein.
4. Wind Loading: a. The design for wind loading shall be in accordance with ASCE 7-05 and the Florida
b. The rake, associated conveyance equipment and anchorages shall be designed to withstand sustained wind speeds of 140 mph without structural damage.
c. The design for wind loading shall be based on an Importance Factor (I) of 1.3 and Exposure Category C.
d. The debris rake and conveyance equipment shall also be designed to operate without loss of effectiveness during periods with sustained winds of up to 70 mph.
e. The rake Manufacturer shall provide a written certification from a Florida licensed Professional Engineer that the system proposed for use is capable of satisfying the wind load requirements specified herein.
5. Service: The rake and conveyance equipment shall be designed to operate in both continuous and standby operational modes. Standby service is defined as a normally idle piece of equipment that is capable of immediate automatic or manual start-up. The rake shall be energized and shall operate when the pump station is operating. Each pump station operates, on average, approximately 750 hours/year. During the wet season and prolonged rain events it is not uncommon for each pump station to operate continuously for up to 5 days. It should be noted however that there have been instances where each pump station has operated continuously for 35 days.
6. Intake Design: The rake and conveyance equipment shall be mounted and secured to the proposed service bridge. The equipment shall be positioned on the upstream side of the bridge and shall be limited to the area shown on the Contract Drawings. The minimum clear bridge width between the debris conveyance equipment and other obstructions shall be maintained.
7. Safety: All debris rake and conveyance equipment shall comply with the applicable provisions of the Federal Occupational Safety and Health Standards. The rake and conveyance equipment shall be equipped with safety devices such as coupling guards, zero speed switches, emergency shutdown pull string and mushroom push-buttons, etc.
8. Load Limiting Device: The rake unit(s) shall be supplied with load limiting devices that shut down the rake and signal an alarm condition back to the control panel when the pull force on the rake units exceeds the setting of the load limiting device.
9. Removal and Reinstallation: The debris rake system shall be capable of being removed from service to allow access to the debris rack. The rake equipment shall require minimal dismantling necessary to facilitate this maintenance requirement and shall be designed for easy reinstallation. No cutting or welding shall be required to remove and/or reinstall the rake system.
B. All rake and conveyance system components shall be furnished by a single Manufacturer that meets the requirements of paragraph 1.04. Any other Manufacturer proposed by the CONTRACTOR other than those specifically named herein shall demonstrate, to the satisfaction of the DISTRICT, that the quality of its equipment is at least equal to the equipment fabricated by those Manufacturers specifically named herein and fully complies with the requirements of this specification.
C. Acceptable Manufacturers: 1. Duperon Corporation 2. D & J Machinery, Inc. 3. DISTRICT approved equal
D. Product Substitutions: The CONTRACTOR is specifically advised that all products provided shall be in strict conformance with this specification and that no exceptions to any of the stated requirements will be permitted. In general, no product substitutions will be approved unless the CONTRACTOR can substantiate complete conformance of the proposed product substitution with all requirements of this specification. All product substitution requests shall be completed in accordance with SECTION 01630.
The mechanical rake units to be provided as part of the debris rake collection system shall conform to and meet the following requirements.
A. The mechanical debris rake system shall be capable of cleaning vegetation and other debris across the entire width of the canal. Each rake unit shall be designed to deposit collected screenings onto a common horizontal belt conveyor located on the service bridge.
B. The mechanical rake units shall be shall be inclined 30-degrees from the vertical plane to match the proposed inclination angle of the debris rack system. The maximum width of each mechanical rake unit shall be 12 feet.
C. All parts of the mechanism shall be amply proportioned for all stresses that may occur during erection, fabrication, and intermittent or continuous operation.
D. The mechanical rake assembly shall be 304 stainless steel, chain-driven, front-cleaning, front-return type. The chain shall be 316 stainless steel with 304 stainless steel pins. The rake shall consist of a ultra-high molecular weight (UHMW) polypropylene scraper that spans the width of the debris rack and is fiberglass reinforced where required. The scrapers shall not cause damage to the debris rack finish or structure and shall be easily modified by the DISTRICT if necessary to suit future changes in debris conditions. The scrapers shall be approximately 63 inches apart, or as recommended by the Manufacturer to ensure adequate screenings removal. The scraper shall be designed to fully penetrate the debris rack to ensure complete capture and removal of any collected debris.
E. The rake shall have a head sprocket only, with no sprockets, bearings, or similar drive components permanently installed underwater at any upstream water level condition.
F. The rake shall clean continuously from bottom to top for the entire width of the scraper.
G. The debris rake system shall be designed to operate continuously.
H. The chain linkage for the drive shall be such that it bends in one direction only, which allows it to become its own lower sprocket and frame. The chain shall also have the ability to deflect around large objects such as tires, logs, etc. to avoid shutting down the unit. The chain links shall be type 316 stainless steel with type 304 stainless steel pins.
I. Chain slides and return guides shall be 304 stainless steel to support and guide the scrapers in the proper track as recommended by the Manufacturer.
J. A stripper assembly shall be installed on the raking device, as recommended by the Manufacturer, to assist in removing debris from the scrapers. The stripper assembly shall be fabricated of 304 stainless steel.
K. Each rake unit shall be equipped with a speed reducer to provide the required output speed. The drive unit shall have a coated, CL40 cast iron drive sprocket and end castings. The drive shaft shall be 316 stainless steel.
L. Bearings shall be greaseable, ball bearing type, non-self-aligning, sealed and lubricated, with a radial load rating as required for the intended service. Underwater bearings of any kind are not acceptable. The layout of the mechanical rake equipment shall allow for easy access to all the major operating parts of the mechanism for maintenance, cleaning and repair. All lubrication fittings which are not easily accessible shall be modified and equipped with 316 stainless steel tubing to extend the grease fittings to the nearest accessible location for ease of maintenance. All stainless steel tubing and grease fitting shall be rigidly secured using 316 stainless steel fasteners and clips as required.
M. The mounting and support frame for the mechanical rake drive assembly shall be fabricated of type 316 stainless steel. All bolted connections shall be made with a minimum of two bolts.
N. Each raking unit shall operate independently with its own drive unit and controls.
O. Each rake shall be driven with an electrically operated gear motor sized for the intended loads. The electric gear motors for the units to be installed at each pump station shall be 1/8th hp, single-phase, 60 cycle, 120/240 VAC. Each of the motors provided shall be a Sumitomo integral gear motor (or approved equal) capable of operating the scrapers and chain at approximately 28+/- inches per
minute. All electric motors shall be totally enclosed, fan cooled, type, suitable for outdoor service and shall be driven by NEMA rated across the line motor starters.
P. A reversing starter which is properly sized for the required loading shall be provided for each drive motor. The starter shall be mounted within the main control panel. Sufficient starter contacts shall be provided to open all motor leads when the motor is de-energized. The starter shall be interlocked electrically and mechanically to prevent energizing forward and reverse contactors simultaneously.
Q. Each rake in the system shall be controlled from a single central main control panel, either manually or automatically, located inside the pump station building, and from local push button stations located at the rake structure. Local push-button stations for controlling rake mechanism shall be mounted in a NEMA 4X 316 stainless steel enclosures. The main control panel enclosure shall be rated NEMA 12 for indoor use. All control panels shall be built by a UL 508A panel builder per UL 508A standards and labeled accordingly to UL 508A standards.
2.04 SCREENINGS BELT CONVEYOR:
A. The screenings belt conveyor shall transport the debris from the rake mechanism to the disposal area shown on the Contract Drawings. The conveyor model shall be fully compatible with the debris rake system and work as a unit and shall have similar safety and shutdown safeguards with all controls interlocked with the debris rake system. The conveyor design shall be the responsibility of the rake Manufacturer to ensure complete compatibility with the debris rake units. The belt conveyor shall also be capable of operating automatically or manually. When operating in the manual mode all safety features shall be enabled.
B. The conveyor shall be a flat roller bed belt conveyor with integrated side walls designed to handle wet loose material that can be expected from the debris collection operation at the intake side of the pump station. The rake and conveyor shall be designed to withstand, without any damage, the free fall of a 1,000 lbs object from a free fall discharge height of 5-feet. Side rails or guides shall be provided to ensure the debris is contained in the conveyor until discharged at the end. The side rails and guides shall be a minimum of 24-inches high, shall be pitched, as required, to receive collected screenings from the rake units and shall be fabricated of 316 stainless steel. The rails and guides shall be designed and fabricated to prevent screening material from becoming jammed, wedged or bound between the conveyor belt and the frame and/or idlers and pulleys. Conveyor designs which fail to include provisions to account for these potential issues are not acceptable.
C. Mechanical/Structural Components: The materials of the conveyor shall be corrosive resistant, durable and suitable for the intended service. The following materials shall be considered the minimum acceptable for the major components of the conveyor unit:
ITEM MATERIAL
Structural support members Stainless steel - ASTM A276 type 304
Rollers, other conveyor bed items Stainless Steel – ASTM A276 type 316L
Drive Components Stainless Steel – ASTM A276 type 316L
Speed Reducer Fully enclosed, weatherproof
Chain drives, pulleys, etc. Fully enclosed, weatherproof
D. The conveyor belt shall be minimum 30-inches wide (maximum 36-inches wide) and be constructed of uniform ply and covering. The conveyor belt shall have an adequate number of plies (minimum two) and be of sufficient weight so that the maximum belt tension does not exceed 75% of the belt Manufacturer’s allowable tension recommendation. Belt shall be designed to withstand maximum operating and starting tensions when fully loaded and to bend properly over the idlers and drive pulleys without overstressing the belt covering, carcass or splice. Covers shall be oil resistant, with
minimum 1/4-inch cover on carrying side and minimum 1/8-inch cover on the bottom side. The conveyor belt profile on the carrying side shall be provided with either cleats or a chevron patterned cover. The layout and size of the cleats or pattern shall be determined by the Manufacturer and shall be as required to prevent material roll back when traversing the incline section of the unit. Conveyor belt ends shall be spliced using a stainless steel mechanical splice. The splice shall have a minimum efficiency of 100% of the belt Manufacturer’s allowable tension recommendations. The belt shall be manufactured by Goodyear, Georgia Duck or DISTRICT approved equal.
E. Idlers: Idlers shall be CEMA Class C, non-metallic rollers. Idler bearings shall be tapered roller type with a minimum B-10 life of 60,000 hours. Each bearing shall be sealed using double seals using a contact seal to exclude dirt and triple-labyrinth seal to retain lubricant. The idlers shall be self lubricating and require no grease fittings. Idlers shall be of rigid shaft, single-roller type. Idler rollers shall be provided with a minimum 1/8-inch thick urethane covers. Carrying idlers shall be spaced by the Manufacturer as required to convey the screenings material but shall not exceed 2-feet at belt loading locations and no more than 3-feet at all other locations. Return idler spacing shall be spaced by the Manufacturer but shall not exceed 5-feet. Idlers shall also be provided as required at the point where the belt conveyor transitions from a horizontal profile to an incline profile, as required, to minimize belt stress. The calculated belt sag across all idlers shall not exceed 2% of the idler spacing under fully loaded conditions. Idler frames and brackets shall be fabricated of stainless steel.
F. Pulleys: Pulleys shall be of the welded stainless steel drum type with grooved lagging. The lagging shall be minimum 1/2-inch thick, with 1/4-inch deep herringbone grooves, and shall be a minimum 60 durometer hardness, vulcanized rubber. Pulley shafts shall be ANSI C1045 steel. Pulleys shall be keyed to the shafts. Pulley shafts shall be supported by roller-bearing pillow blocks which are in turn secured to the belt conveyor structural frame. Bearings shall be self aligning rollers with a minimum B-10 life of 60,000 hours. Bearing adjustment screws shall be provided on each end of the bearing base to aid in alignment. Pulley shaft bearings shall be lubricated from a single grease fitting located on the access bridge side of the pulley. All grease fittings shall be zerk type. The tail pulley shall be equipped with a take-up assembly with a minimum adjustment of 18-inches. The take up assembly shall be a screw type which is capable of tensioning and loosening the belt through the turning of capture nuts located on either side of the supporting frame. The take up assembly shall be capable of being adjusted while the conveyor belt is fully loaded. The entire take up assembly shall be 316 stainless steel.
G. Framing members and supports: All conveyor frame members and supports shall be fabricated of ASTM A-36 steel plate and structural shapes. The main structural frame shall be fabricated from structural grade channel sections. All steel shall be hot-dipped galvanized in accordance with ASTM A123 and/or ASTM A153 following fabrication. All structural steel components shall be hot-dip zinc galvanized in accordance with ASTM A-123 and SECTION 05100 following fabrication. All holes required for assembly and/or connection of the conveyor components shall be pre-drilled or punched prior to the galvanizing process. Field drilling and/or punching of any galvanized steel component will not be permitted. All structural members shall be larger than ¼-inch thick. Side closeouts shall be a minimum 1/8-inch thick. The frame shall include adequate supports for head and tail section machinery as well as all supports required for the idlers. The frame shall be provided with frame support legs spaced at an interval to be determined by the Manufacturer. The support legs shall be equipped with base plates to facilitate anchoring the conveyor to the access bridge. Each base plate shall be anchored to the access bridge using stainless steel adhesive anchor bolts. The number of anchor bolts, size, orientation and embedment depth shall be per the Manufacturer and as required to meet the requirements of the Florida Building Code. All bolted connections shall be made with a minimum of two bolts.
H. The belt conveyor shall be installed on the service bridge and run to the disposal area. The conveyor shall include an inclined section that will lift the collected screenings to allow for a free fall discharge to the disposal area. The angle of inclination of the conveyor shall be per the Manufacturer’s recommendations but in general shall be limited to a maximum angle of inclination of 25-degrees for non-cleated belts.
I. The belt conveyor shall be driven with an electrically operated gear motor sized for the intended loads. The electric gear motor for the unit installed at Pump Station S-133 shall be 5 hp, single-phase, 60 cycle, 120/240 VAC. The electrical gear motor for the unit installed at Pump Station S-135 shall be 3 hp, three-phase, 60 cycle, 120/2208 VAC. Each motor shall be a Sumitomo integral gear motor (or approved equal) capable of operating the conveyor at a speed of 30 ft per minute. The electric motors shall be totally enclosed, fan cooled, type, suitable for outdoor service and shall be driven by a NEMA rated across the line motor starters.
J. Safety Guards: Safety guards shall be provided for all exposed gears, chains, sprockets and flexible couplings. Guards shall be fabricated of 304 stainless steel and be painted safety orange. Guards shall be rigidly supported and shall be properly secured using stainless steel hardware. Guards shall be removable to facilitate any required maintenance. The conveyor equipment shall comply with the applicable provisions of the Federal Occupational Safety and Health Administration (OSHA) standards.
K. Safety Devices: The conveyor shall be equipped with the following safety devices: 1. Emergency trip cord running on the side of the conveyor which is accessible from the service
bridge. Trip cabling shall be minimum 3/16-inch stainless steel cable with orange color nylon sheathing. Cabling shall be supported by stainless eyebolts a minimum every 10-feet. Wired clamps shall be stainless steel.
2. Two (2) safety stop switches which meet the applicable OSHA standards. The safety stop switches shall be located at each end of the conveyor. The safety switches shall be housed in a 316 stainless steel NEMA 4X enclosure mounted directly to the conveyor frame.
3. A zero speed switch shall be directly connected to the tail pulley. The switch shall be housed in a 316 stainless steel NEMA 4X enclosure mounted directly to the conveyor frame.
2.05 DEBRIS REMOVAL SYSTEM CONTROLS:
A. Operational Control: The operation of the rake and conveyance equipment shall be determined by the position of an “Auto-Off-Manual” selector switch located on the Control Panel. “Auto” mode shall interlock the rake and conveyance equipment with the operation of the pump station pumps and require no operator interface for proper operation of the system. “Manual” mode shall allow operation of the system, or any of the system components, by an operator while maintaining all safety features and interlocks.
B. Electrical Controls: The electrical control panel for the rake/conveyance equipment shall be mounted on the inside of the pump station building, or as otherwise indicated on the Contract Drawings, with local controls, disconnects, etc. as required located adjacent to rake equipment on the service bridge. The control panel enclosure shall be rated NEMA type 12. Local disconnects, enclosures for local controls, etc. shall be rated NEMA type 4X 316 stainless steel. All components of the control system, control schematics, and other electrical components shall be submitted to the DISTRICT for approval in accordance with paragraph 1.03. The controls for the debris collection system shall be integrated into a single control panel. All equipment shall be interlocked as required to sequence the operation of the individual components and to ensure that the system safety features are continuously enabled. Refer to the Contract Drawings.
2.06 SPARE PARTS: All spare parts shall be duplicates of the original parts furnished and shall be interchangeable. Spare parts shall be packed in crates. The CONTRACTOR shall furnish one set of replacement parts for all of the wear components of the rake and conveyance equipment. Wear components are defined as those structural, mechanical and electrical components that are subject to replacement due to wear for a cycle time less than the twenty five year service life of the debris removal system, excluding motors, drive units and/or consumables.
2.07 SPECIAL TOOLS: The CONTRACTOR shall furnish one set of “special tools” required for complete assembly, disassembly, or maintenance of the rake and conveyance equipment. Special tools are defined as oversized or specially dimensioned tools, special attachments or fixtures, or any similar items.
2.08 PROTECTIVE COATINGS: The units shall have the following paint system applications. See specification SECTION 09900 Protective Coatings, System S-3 for additional details.
A. Shop Painting: All ferrous metals including all ancillary items such as guards shall have a shop applied protective coating as indicated below. The CONTRACTOR shall submit the Manufacturer’s product data for the proposed paint system in accordance with paragraph 1.03. Surfaces of galvanized steel, stainless steel, aluminum, bronze, fiberglass, or neoprene shall not be coated.
B. Field Painting: CONTRACTOR shall touch-up coatings damaged during shipment or installation.
PART 3 - EXECUTION
3.01 FACTORY TESTS: The equipment Manufacturer shall conduct all necessary factory performance tests to insure that the mechanical and electrical operation of the equipment to be supplied is in accordance with the specifications and free of defects prior to shipment. The factory test shall include testing of all functional and control interlocks as well as all safety interlocks. All such tests shall be documented by the Manufacturer and supplied to the DISTRICT upon request.
3.02 FACTORY INSPECTIONS: The DISTRICT may make periodic visits to the Manufacturer’s plant to inspect the fabrication and assembly of the equipment. The Manufacturer shall have detailed fabrication and assembly drawings available for review upon request. Drawing details shall include all dimensions, tolerances, shaft clearances, and bearings. The Manufacturer shall also have available at the time of the inspections purchase orders, mill orders, or shop orders including certified material test reports that indicate components and/or materials to be used in the equipment’s manufacture. The DISTRICT shall review these records, drawing details and the unit for compliance with the specifications as well as standard industry practice. The DISTRICT shall provide a written report to the CONTRACTOR of the inspection that will include those items observed to be in non-compliance with the specifications. It will be the CONTRACTOR’S responsibility to ensure that all items are corrected by the Manufacturer. Re-inspection of the items in non-compliance may be requested by the DISTRICT.
3.03 FACTORY ASSEMBLY: All equipment shall be completely shop assembled and aligned prior to shipping. Tolerances shall not exceed those specified or shown in the Manufacturer’s drawings. Rotating elements shall be checked for binding. The DISTRICT shall witness the shop assembly unless otherwise stated. After completion of the specified factory tests, equipment shall be prepared for shipment with the minimum amount of disassembly. Any components removed for shipping shall be match-marked prior to removal and shipment.
3.04 STORAGE: All equipment placed in storage shall be stored indoors, protected from the weather, humidity and temperature variations, dirt, dust and other contaminants. The CONTRACTOR shall locate and procure all off-site storage that may be required throughout the life of the Contract. All on-site and off-site storage provisions are subject to approval by the DISTRICT.
3.05 INSTALLATION: Installation, start-up and testing of all equipment and associated construction shall conform to Manufacturer's recommendations and the installation and erection manual. The Manufacturer's field representative shall meet with CONTRACTOR to provide all necessary guidelines and specifications for installation and testing of equipment supplied. The Manufacturer’s field representative shall also inspect all equipment after installation and prior to start-up. Upon completion of the installation the equipment Manufacturer shall certify in writing to the DISTRICT that the equipment has been installed in accordance with the Manufacturer’s installation and erection manuals.
A. Equipment Leveling: The rake/conveyance equipment shall be installed and leveled by millwrights experienced in setting and leveling heavy equipment. The CONTRACTOR shall level the base plates against the anchor bolt nuts using steel leveling blocks and shims at every bolt location to a maximum tolerance of 0.005 in./ft. unless otherwise recommended by the Manufacturer. Leveling equipment shall be precision surveying equipment. The void space below equipment base plates shall be filled with non-shrink grout conforming to the requirements of specification SECTION 03600. The grout shall be placed in one continuous operation and in a manner to avoid air entrapment. After the grout has attained the required compressive strength, remove the leveling blocks and shims and torque the
anchor bolts to the clamping force required by the equipment Manufacturer. Torque bolts in increments of not more than 25 percent of the final value in an alternating pattern to avoid stress concentration on the grout surface. Void spaces created by the removal of the leveling blocks and shims shall be filled with grout after the anchor bolts have been tightened to their final value.
B. Equipment Alignment: All equipment shall be aligned in accordance with the Manufacturer’s installation and erection manual.
3.06 FIELD OPERATING TEST:
A. General: All field operating and equipment tests shall be performed by the CONTRACTOR and in the presence of the DISTRICT. The Manufacturer's field representative shall be present during all operating tests. The CONTRACTOR’S instrumentation and controls subcontractor and/or electrical subcontractor shall also be present during all operating tests. The CONTRACTOR shall be responsible for the coordination of the various trades and responsible parties for the successful performance of all field tests. Should the tests reveal a design deficiency or a manufacturing error, the problem shall be promptly corrected by, and at the expense of, the CONTRACTOR.
B. Operating Tests: Conduct operational tests as necessary to determine that the performance of equipment and controls is as specified. Tests shall consist of placing all equipment in operation and performing functional tests and check-out of all system components.
C. Make all necessary equipment adjustments and corrective work indicated by tests.
D. Submit a written test report of all tests performed and their results to the DISTRICT.
3.07 POST CONSTRUCTION INSPECTIONS:
A. Sixty (60) Day Check: Recheck equipment for alignment in accordance with specification SECTION 01670 Equipment Alignment Testing, after the equipment has been placed in operation for approximately 60 days. All alignment checks shall be performed by an independent qualified testing consultant with all costs borne by the DISTRICT. If the alignment variation exceeds the allowable limits as indicated in the referenced section, the CONTRACTOR shall investigate the cause of the problem and, if it is determined to be a defect with the equipment or its installation, the CONTRACTOR shall take all necessary action to correct the problem.
END OF SECTION
Spec. Standard: Not Applicable 11288-1 Created: 02/15/12
SECTION 11288 COMBINATION GATES
PART 1 - GENERAL
1.01 SUMMARY:
A. This Section includes self-contained fabricated stainless steel combination gates, gate operators, and accessories. The gate shall consist of a sliding gate leaf with an integral flap gate.
B. Furnish the number and type of gates and operators as specified.
C. Related Work Specified Elsewhere:
1. SECTION 09900 Protective Coatings
1.02 REFERENCES:
A. Applicable Standards: The latest edition of the following codes or standards shall apply to the Work of this Section.
1. American Water Works Association (AWWA):
a. ANSI/AWWA C513, Standard for Open-Channel, Fabricated-Metal Gates and Open-Channel, Fabricated-Metal Weir Gates
b. ANSI/ AWWA C540, Standard for Power-Actuating Devices for Valves and Slide Gates
2. American Society for Testing and Materials (ASTM):
a. A276 Standard Specification for Stainless Steel Bars and Shapes
b. A240 Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications
c. A582 Standard Specification for Free-Machining Stainless Steel Bars
d. D4020 Specification for Ultra-High-Molecular-Weight Polyethylene Molding and Extrusion Materials
e. D412 Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers—Tension
f. D2240 Standard Test Method for Rubber Property—Durometer Hardness
g. D395 Standard Test Methods for Rubber Property—Compression Set
h. F593 Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs
i. F594 Standard Specification for Stainless Steel Nuts
j. D2000 Standard Classification System for Rubber Products in Automotive Applications
1.03 SUBMITTALS:
A. Submit as specified in SECTION 01300.
B. Include, but not limited to, the following:
1. Catalog data and illustrations showing principal parts and materials
2. Spare parts list
3. Assembly, disassembly and repair instructions and procedures
4. Detailed layout dimensions
5. Protective coating system for non stainless steel components
6. Field leakage testing procedures
7. For electric motor driven operators: Schematic and wiring diagrams indicating interconnecting wiring between the operator, gate control panel and push button station
8. Installation, operation, and maintenance manuals
Spec. Standard: Not Applicable 11288-2 Created: 02/15/12
1.04 QUALITY ASSURANCE:
A. The combination gate Manufacturer shall be experienced in the design and manufacture of equipment and accessories for water control gates for a minimum period of 10 years. Specifically, the Manufacturer shall have experience with fabricating and supplying combination gates, as specified herein, for similar projects. The Manufacturer shall be required to submit for review all similar projects where he has fabricated and supplied combination gates. The DISTRICT reserves the right to disqualify any Manufacturer which is unable to substantiate adequate experience in the fabrication of combination gates. The DISTRICT shall be the sole determiner on what constitutes adequate experience.
1.05 DELIVERY, STORAGE, AND HANDLING:
A. Shipment Preparation: Prepare equipment and materials for shipment in a manner to facilitate unloading and handling, and to protect against damage or unnecessary exposure in transit and storage. Include:
1. Crates or other suitable packaging materials
2. Covers and other means to prevent corrosion, moisture damage, mechanical injury and accumulation of dirt in motors, electrical equipment and machinery
3. Suitable rust-preventive compound on exposed machined surfaces and unpainted iron and steel
4. Grease packing or oil lubrication in all bearings and similar items
B. Marking:
1. Tag or mark each item of equipment or material as identified in the delivery schedule or on Submittals and include complete packing lists and bills of material with each shipment. Each piece of every item need not be marked separately provided that all pieces of each item are packed or bundled together and the packages or bundles are properly tagged and marked.
2. Mark partial deliveries of component parts of equipment to identify the equipment, to permit easy accumulation of parts, and to facilitate assembly.
1.06 WARRANTY:
A. The Manufacturer shall warrant the EQUIPMENT, MATERIALS and PRODUCTS specified in this Section against defective materials and workmanship with the Manufacturer’s standard warranty, but for no less than one year from the date of Substantial Completion, and as described in Article 13 of Section 00700 - General Terms and Conditions.
B. The CONTRACTOR shall warrant the Work against defects for one year from the date of Substantial Completion and as described in Article 13 of Section 00700 - General Terms and Conditions.
PART 2 - PRODUCTS
2.01 ACCEPTABLE MANUFACTURERS:
A. Combination Gates:
1. Whipps, Inc.
2. DISTRICT approved equal
B. Gate Operators:
1. Auma
2. EIM
3. Limitorque
4. Rotork
5. DISTRICT approved equal
Spec. Standard: Not Applicable 11288-3 Created: 02/15/12
2.02 COMBINATION GATES:
A. Design Requirements:
1. The gates supplied shall be motor driven, rising stem, self-contained style combination slide and flap gate. Gate size, mounting type, seating and unseating heads, bottom seal elevations,pedestal or yoke elevations, and operator types shall be in accordance with Table 1:
Table 1 – Combination Gates
LocationOpening
SizeMounting Type
Design SeatingHead
Design Unseating
Head2
Bottom Seal
Elevation
Yoke Mounted Operator Elevation
Operator Type
S-129 Bypass Culvert Outlet
96-inch dia.
Self-Contained, Face Mounted
18.5-ft1 11.0-ft1 5.0-ft1 27.0-ft1Electric Motor Driven
S-131 Bypass Culvert Outlet
96-inch dia.
Self-Contained, Face Mounted
18.5-ft1 11.0-ft1 5.0ft1 27.0-ft1Electric Motor Driven
1 Elevations shown in NGVD29
2 Gate flap shall open as described in 2.02A.2 below
2. The flap portion of the gate shall be designed to open when the water level elevation in the rim canal is no greater than 4-inches higher than the water level elevation in Lake Okeechobee during periods when the downstream side of the flap gate is fully submerged meaning that the crown of the bypass culvert is submerged. During periods when the water level elevation on the downstream side of the gate (i.e. lakeside) is lower than the crown of the bypass culvert the differential head required to open the flap gate shall be 12-inches or less.
3. The gates provided shall be suitable for operation following periods of inactivity of a year or more.
B. Frames:
1. Frames shall be fabricated from structural members or formed plate to form a rigid one piece frame. The frame configuration shall be flanged back and face mounted. Frames shall be self-contained with yoke mounted gate operators as shown on the Drawings.
a. For yoke mounted gate operators, the structural members shall be designed to provide the required structural support for the gate operator and the loads produced from the gate operation under worse case design head conditions (for example: design seating head one side of gate with no water on unseating side). The structural members or formed plates of the yoke shall be sized to limit deflections to 1/360 of its span and resist the torque imposed on the yoke by the gate operator.
2. The frames shall be furnished with gate stops to limit the opening of the gate. The gate stops shall be bolted to the frames to allow removal.
3. Furnish a horizontal framing member at top of gate opening. Frame member shall be attached, welded or bolted connection, to the gate frame for mounting of a top seal.
4. The gates shall be secured to the existing cast-in-place concrete bypass outlet headwall as shown on the Drawings. Non-shrink grout shall be used to seal between the frame and concrete mounting surfaces.
C. Slide/Flap:
1. The slide/flap portion of the gate shall be fabricated of flat structural plate (minimum ¼-inchthick), reinforced with structural members or formed plates as required to limit its deflection to 1/360 of the gate’s span under the design head conditions.
2. The flap shall seat at an angle between 3 and 7 degrees to the vertical. Dual hinge arms shall be provided and shall be fabricated of stainless steel structural plate with a minimum thickness of
Spec. Standard: Not Applicable 11288-4 Created: 02/15/12
3/8-inch. Hinge pins shall be stainless steel with a minimum diameter of 1-inch and constructed of solid bar stock.
D. Seals:
1. Side Seals: Seals shall extend from the bottom seal to the top seal and be retained with backing plates and fasteners, as required. Combination gate Manufacturer may incorporate the side seals with the sliding leaf guides. If combined into a single assembly the seal/guide shall meet the requirements of 2.02.D.4 and 2.02.E
2. Bottom seal: Seal shall be incorporated into a structural member or formed plate. Bottom sealarrangement shall be coordinated with frame configuration and type of frame mounting, reference 2.02.B of this specification.
3. Top Seal: The top seal shall be attached to the horizontal framing member as described in 2.02.B.3. The top seal shall be retained with backing plates and fasteners as required.
4. Seals shall meet specified maximum leakage rate at the design seating head conditions. Leakage rate shall be field verified by the DISTRICT after installation of the gate/frame assembly under design head conditions.
a. Specified seating head leakage rate: 0.1 GPM per linear foot of seal
E. Slide Guides:
1. Guides for the sliding gate leaf shall run the full length of the frame and prevent metal to metal contact between the slide and the frame.
2. The guides shall be designed to accommodate the total thrust produced by water pressure at the design head conditions.
3. The guides shall be mechanically interlocked or attached to the frame.
F. Stem, Stem Couplings, and Stem Guides:
1. Stems:
a. The L/r ratio of an unsupported stem shall be less than 200. Furnish stem guides where required to limit the unsupported stem length. Depending on operator type the stem shall be designed to:
i. Transmit in compression a minimum of two times the rated output of a manual crank type gate actuator for manual crank type operators.
ii. Transmit in compression a minimum of 1.25 times the output thrust of an electric motor driven actuator in the stalled condition.
b. Stem threads shall be machine cut Acme type. The number of threads per inch and pitchshall be selected by the gate manufacturer to work most efficiently with the lift mechanism used and the gate speed specified.
c. A stop nut shall be furnished on the stem to limit the downward travel of the gate. The stop nut shall be fabricated from a single piece matching the stem material, tapped to match the stem, and drilled and tapped for a minimum of two 3/8 set screws.
2. The stem shall be connected to the top of the gate with a bolted connection designed to withstand the maximum design forces imposed by the operator under design head conditions. Connection shall be designed with a minimum safety factor of 2.
3. Stem guides, where required, to limit stem deflection shall be bronze or polymer bushed. Stem guides shall be factory aligned.
4. Furnish a bellows type stem protection boot for the entire length of the exposed stem from the top of the gate to the underside of the yoke or pedestal as applicable. The stem boot shall be reinforced to minimize contact between the boot and stem. The boot shall be furnished withnon metallic zipper running the full length of the boot to allow removal without disassembly of the gate/stem assembly.
5. Furnish a rigid protective cover for the stem section above the operator. The cover shall be made of clear butyrate plastic that will not discolor or become opaque for at least five years after installation. The cover shall be of sufficient diameter and length to permit full travel of the
Spec. Standard: Not Applicable 11288-5 Created: 02/15/12
threaded stem without obstruction. The top of the stem cover shall be closed and vented. The bottom end of the stem cover shall be vented, drained, and mounted in a housing or adapter plate for easy field-mounting installation. The stem cover shall be graduated to allow for visual indication/determination of the gate position.
G. Anchor Bolts or Studs:
1. The Manufacturer shall furnish all anchor bolts and fasteners for the installation of the gate, frame, and operator assembly including but not limited to the following:
a. Gate frames
b. Stem guides
c. Operator pedestals
The Manufacturer shall be solely responsible for the size and number of anchor bolts to be used. The anchors shall be adequately sized and arranged as required to account for all static and dynamic loads imposed on the gate.
H. Dogging Slings:
1. The gates shall be supplied with two (2) dogging slings which are designed to facilitate removal of the gate operator with the slide in the fully open position. The dogging slings shall be minimum 3/8-inch, 6 x 37 classification with an independent wire rope core (IWRC), 316 stainless steel wire rope. Each dogging sling shall be capable of being shackled to a lifting bracket which is either welded to or integral to the slide. The lifting brackets shall be positioned on either side of the gate stem and shall not interfere with the operation of the gate or the gate position sensor indicator pointer rod. The opposing end of the dogging slings shall be shackled to an eyebolt and support plate which is welded to the top structural member of the self-contained gate frame. The shackles shall be min. 3/8-inch 316 stainless steel. The support plate and eyebolt shall be fabricated of 304L stainless steel.
I. Materials:
1. Gate frame, yoke, slide leaf, flap gate, stem guides and miscellaneous fabrications: ASTM A276 and A240, Type 304L Stainless Steel
2. Seal backing bars: ASTM A276, Type 304L Stainless Steel
3. Stem: ASTM A276, Type 304L Stainless Steel
4. Fasteners and anchor bolts: ASTM F593 and F594 Type 316 Stainless Steel
5. Stem Boot: Nylon reinforced Goretex
6. Gasket material: EDPM
7. Slide Guides: Ultra high molecular weight polyethylene (UHMWPE) meeting the requirements of ASTM D4020
8. Bottom Seal Material: Resilient neoprene meeting the requirements of ASTM D-2000 grade 2 BC-510
9. Seals: Rubber J-type meeting the requirements of ASTM D2000 grade 2 BC 615 or fabricated from ultra high molecular weight polyethylene (UHMWPE) meeting the requirements of ASTM D4020
10. Stem Cover: Clear butyrate or polycarbonate
2.03 GATE OPERATORS: Each combination gate shall be supplied with an appropriately sized gate operator. The gate operator shall be sized and supplied by the gate Manufacturer for complete system responsibility. The Manufacturer shall provide gate operators as indicated herein.
Spec. Standard: Not Applicable 11288-6 Created: 02/15/12
A. Electric motor driven Operators:
1. Basic operator: The electric gate operator shall include the motor, reduction gearing, limit switch gearing, position limit switches, torque switches, declutch lever, drive nut, and handwheel as a self-contained unit and be mounted to the pedestal or yoke as applicable. The operator shall be capable of opening and closing the gate at a nominal speed of 6 inches per minute and the actuator shall also be capable of opening and closing the gate at intermittent positions.
2. Enclosure:
a. The gate actuator motor and all electrical enclosures shall have NEMA 4 and 6 ratings.Enclosures shall be constructed from cast iron with stainless steel external hardware.
b. Electrical Controls: The actuator shall be furnished with power and control terminal strips, limit switches, torque switches, all housed in a control compartment meeting NEMA 4 (watertight). The use of printed circuit boards as a substitute for interconnecting wiring inside of the operator is not acceptable. The enclosure shall have a bonded o-ring seal and a hinged cover. Cover bolting shall be captive stainless machinescrews.
3. Open-close service controls: The reversing contactor, pushbuttons, indicating lights, etc. shall be located within a NEMA 4 (water tight) control panel with separate push button controls located adjacent to the actuator.
4. Motor: The motor shall be totally enclosed fan cooled (TEFC), C-face capacitor start induction run 4 lead 240 VAC or 6 lead 120/240 VAC single phase, or a 208 VAC three phase per the electrical drawings and specifically designed for gate actuator service. Motor insulation shall be a minimum NEMA Class F, with a maximum continuous winding temperature rating of 190degrees C (rise plus ambient) for the duty cycle specified. The motor shall be of sufficient capacity to open or close the gate at the maximum design head conditions and shall be capable of operating at plus or minus 10 percent of specified voltage. The motor duty rating shall be sufficient for one complete cycle, defined as opening the gate from a closed position to fully open and then returning to a fully closed position without exceeding its temperature rating. Motor bearings shall be of the anti-friction type, and permanently lubricated. The motor shall be an independent sub-assembly such that the power gearing shall not be an integral part of the motor assembly, to allow for motor or gear changes dictated by system operation requirements. The motor shall be equipped with internal thermal class B contacts to protect against motor overload and 120 volt AC heaters.
5. Power Gearing: The actuator shall be a multiple reduction unit with power gearing consisting of spur, helical, or bevel gears, and worm gearing. The spur, helical, or bevel gearing and worm shall be of hardened alloy steel, and the worm gear shall be alloy bronze. All gearing shall be accurately cut. Non-metallic, aluminum or cast gearing shall not be allowed. Anti-friction bearings shall be used throughout.
6. Lubrication: All rotating power train components shall be immersed in grease with provisions for inspection and re-lubrication without disassembly. Lubricants shall be suitable for ambient conditions of minus 20 degrees Fahrenheit to 150 degrees Fahrenheit. Adequate seals shall be provided on all shafting.
7. Self-Locking Feature: Actuator gearing shall be self-locking.
8. Manual Operation: A metal hand wheel shall be provided for manual operation with an arrow to indicate “open” rotation. Manual operation of the Gates shall require no more than 40 pounds of force. The hand wheel shall not rotate during motor operation. An inoperative motor shall not prevent manual operation. When in the manual operating mode, the actuator will remain in this mode until the motor is energized, at which time the actuator will automatically return to electric operation. Movement from motor operation to hand wheel operation shall be accomplished by a positive padlockable declutch lever which mechanically disengages the motor and related gearing. It shall be impossible for simultaneous manual and motor operation to occur. Friction type declutch mechanism are not acceptable.
9. Stem Nut: The gate actuator shall have a removable stem nut or drive bushing of high tensile bronze or other material compatible with the stem material.
Spec. Standard: Not Applicable 11288-7 Created: 02/15/12
10. Position Limit Switches: Position limit switches shall be geared to the drive mechanism and in step with stem position whether operation is by the electric motor or manual hand crank. The associated gearing shall be an integral part of the operator. Limit switch gearing shall be made of bronze or stainless steel, grease lubricated, and totally enclosed to prevent dirt and foreign matter from entering the gear train. Switches shall be adjustable, allowing for trip points from fully open to fully closed positions of gate travel. They shall not be subject to breakage or slippage due to over-travel. Limit switch contacts shall be heavy duty, silver-plated with wiping action. The actuators shall have 2 NC and 2 NO switches for each end of travel position. Switch design shall permit visual verification of switch position without disassembly.
11. Torque Switch: Each gate actuator shall be equipped with a switch that will interrupt the control circuit in both the opening and closing directions when gate torque overload occurs or when gates require torque seating in the closed or open position. Four torque switches shall be furnished, two for each direction. The torque switches shall have graduated dials for both open and close directions of travel and each shall be independently adjustable, with a positive means to limit the adjustability so as not to exceed the actuator output torque capability. Switch design shall permit visible verification of switch position without disassembly.
12. Switch Contact Ratings: The position limit switch and torque switch shall be rated 240 volts, 5 amps continuous per NEMA standard ICS 2-125.
13. Stem Lubrication: Furnish an automated stem oiler with reservoir to lubricate both sections ofthe gate stem (above and below the drive nut). The oiler shall have a 1 quart min capacity with a120VAC solenoid valve electrically interlocked with operator motor. The stem oiler and/or drive nut shall be designed such that lubricating oil is distributed along the full length of the drive nut, ensuring that all threads from top to bottom, and regardless of the direction of stem travel, are lubricated. The lubricating system shall be capable of using 220 weight petroleum based lubricants. The oiler shall be manufactured by Essex Brass Model #377 or approved equivalent.
14. Position Indicator: Local position indication shall be provided by a dial window indicator located on the limit switch compartment cover, and labeled in 5% increments from 0 to 100% open.
15. Coating System: Surfaces shall be supplied with a protective coating system as specified in SECTION 09900.
PART 3 - EXECUTION
3.01 INSTALLATION:
A. Comply with provisions of AWWA C560, C540 and as specified.
B. Lubricate all bearings and gears before placing gates in operation.
C. Provide Manufacturer's field services as specified in DIVISION 1.
D. Perform equipment tests during and after start-up to determine if equipment is performing as specified.
1. For electric motor driven operators:
a. A Manufacturer’s field service technician shall perform the start up of the gate operator.
b. The technician shall accurately set the limit switches.
i. The lower limit shall be set to interrupt the control circuit when the sliding gate leaf firmly makes contact with the bottom seal but before the torque switch opens.
ii. The upper limit shall be set to interrupt the control circuit when the bottom of the gate clears the top seal.
c. The technician shall set the torque switch values to levels recommended by the gate Manufacturer.
A. This Section includes self-contained fabricated stainless steel slide gates, gate operators, and accessories.
B. Furnish the number and type of gates and operators as specified.
C. Related Work Specified Elsewhere:
1. SECTION 09900 Protective Coatings
1.02 REFERENCES:
A. Applicable Standards: The latest edition of the following codes or standards shall apply to the Work of this Section.
1. American Water Works Association (AWWA):
a. ANSI/AWWA C513, Standard for Open-Channel, Fabricated-Metal Slide Gates and Open-Channel, Fabricated-Metal Weir Gates
b. ANSI/ AWWA C540, Standard for Power-Actuating Devices for Valves and Slide Gates
2. American Society for Testing and Materials (ASTM):
a. A276 Standard Specification for Stainless Steel Bars and Shapes
b. A240 Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications
c. A582 Standard Specification for Free-Machining Stainless Steel Bars
d. D4020 Specification for Ultra-High-Molecular-Weight Polyethylene Molding and Extrusion Materials
e. D412 Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers—Tension
f. D2240 Standard Test Method for Rubber Property—Durometer Hardness
g. D395 Standard Test Methods for Rubber Property—Compression Set
h. F593 Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs
i. F594 Standard Specification for Stainless Steel Nuts
j. D2000 Standard Classification System for Rubber Products in Automotive Applications
1.03 SUBMITTALS:
A. Submit as specified in SECTION 01300.
B. Include, but not limited to, the following:
1. Catalog data and illustrations showing principal parts and materials
2. Spare parts list
3. Assembly, disassembly and repair instructions and procedures
5. Protective coating system for non stainless steel components
6. Leakage testing procedures
7. For electric motor driven operators: Schematic and wiring diagrams indicating interconnecting wiring between the operator, gate control panel and push button station
8. Installation, operation, and maintenance manuals
1.04 QUALITY ASSURANCE:
A. Manufacturers shall be experienced in the design and manufacture of equipment and accessories for a minimum period of 5 years.
1.05 DELIVERY, STORAGE, AND HANDLING:
A. Shipment Preparation: Prepare equipment and materials for shipment in a manner to facilitate unloading and handling, and to protect against damage or unnecessary exposure in transit and storage. Include:
1. Crates or other suitable packaging materials
2. Covers and other means to prevent corrosion, moisture damage, mechanical injury and accumulation of dirt in motors, electrical equipment and machinery
3. Suitable rust-preventive compound on exposed machined surfaces and unpainted iron and steel
4. Grease packing or oil lubrication in all bearings and similar items
B. Marking:
1. Tag or mark each item of equipment or material as identified in the delivery schedule or on Submittals and include complete packing lists and bills of material with each shipment. Each piece of every item need not be marked separately provided that all pieces of each item are packed or bundled together and the packages or bundles are properly tagged and marked.
2. Mark partial deliveries of component parts of equipment to identify the equipment, to permit easy accumulation of parts, and to facilitate assembly.
1.06 WARRANTY:
A. The Manufacturer shall warrant the EQUIPMENT, MATERIALS and PRODUCTS specified in this Section against defective materials and workmanship with the Manufacturer’s standard warranty, but for no less than one year from the date of Substantial Completion, and as described in Article 13 of Section 00700 - General Terms and Conditions.
B. The CONTRACTOR shall warrant the Work against defects for one year from the date of Substantial Completion and as described in Article 13 of Section 00700 - General Terms and Conditions.
1. Gate size, mounting type, seating and unseating heads, bottom seal elevations, pedestal or yoke elevations, and operator types shall be in accordance with Table 1:
Table 1 – Slide Gates
LocationOpening
SizeMounting Type
Design SeatingHead
Design Unseating
Head
Bottom Seal
Elevation
Yoke Mounted Operator Elevation
Operator Type
S-129 Bypass Culvert Inlet
96-inch dia.
Self-Contained, Face Mounted
11.0-ft1 17.0-ft1 6.0-ft1 28.25-ft1Electric Motor Driven
S-131 Bypass Culvert Inlet
96-inch dia.
Self-Contained, Face Mounted
11.0-ft1 17.0-ft1 6.0ft1 28.25-ft1Electric Motor Driven
1 Elevations shown in NGVD29
2. Suitable for operation after periods of inactivity of a year or more.
B. Frames:
1. Frames shall be fabricated from structural members or formed plate to form a rigid one piece frame. The frame configuration, for example flange or flat back, channel mount, embedded shall be as specified. Frames shall be self-contained with pedestal mounted gate operators as indicated on the Drawings.
a. For yoke mounted gate operators, the structural members shall be designed to provide the required structural support for the gate operator and the loads produced from the gate operation under worse case design head conditions (for example: design seating head one side of gate with no water on unseating side). The structural members or formed plates of the yoke shall be sized to limit deflections to 1/360 of its span and resist the torque imposed on the yoke by the gate operator. The yoke shall have bolted connections to the frame.
b. For pedestal mounted actuators, the CONTRACTOR shall coordinate the mounting of the pedestal with the structural supports indicated on the drawings. The pedestals shall be fabricated from 304 stainless steel.
2. The frames shall be furnished with gate stops to limit the opening of the gate. The gate stops shall be bolted to the frames to allow removal. Stops shall be located to allow the bottom of the gate to clear the top seal opening plus 6”.
3. Furnish a horizontal framing member at top of gate opening. Frame member shall be attached, welded or bolted connection, to the gate frame for mounting of a top seal.
4. Gasket material shall be furnished to seal between the frame and concrete mounting surfaces where applicable. For example, flat back or flanged type frames
C. Slide:
1. Flat structural plate (minimum ¼” thick), reinforced with structural members or formed platesas required to limit its deflection to 1/360 of the gate’s span under the design head conditions.
2. Slide shall be designed to drain when opened above the water level and not trap debris, soil, etc.
D. Seals:
1. Side Seals: Seals shall extend from the bottom seal to the top seal and be retained with backing plates and fasteners, as required. Slide gate Manufacturer may incorporate the side seals with the slide guides. If combined into a single assembly the seal/guide shall meet the requirements of 2.02.D.4 and 2.02.E
2. Bottom seal: Seal shall be incorporated into a structural member or formed plate. Bottom sealarrangement shall be coordinated with frame configuration and type of frame mounting, reference 2.02.B of this specification.
3. Top Seal: The top seal shall be attached to the horizontal framing member as described in 2.02.B.3. The top seal shall be retained with backing plates and fasteners as required.
4. Seals shall meet specified maximum leakage rates at the design head conditions in both the seating and unseating conditions. Leakage rates shall be field verified by the DISTRICT after installation of the gate/frame assembly under design head conditions.
a. Specified seating head leakage rate: 0.1 GPM per linear foot of seal
b. Specified unseating head leakage rate: 0.2 GPM per linear foot of seal
E. Slide Guides:
1. Guides shall run the full length of the frame and prevent metal to metal contact between the slide and the frame.
2. The guides shall be designed to accommodate the total thrust produced by water pressure at the design head conditions.
3. The guides shall be mechanically interlocked or attached to the frame.
F. Stem, Stem Couplings, and Stem Guides:
1. Stems:
a. The L/r ratio of an unsupported stem shall be less than 200. Furnish stem guides where required to limit the unsupported stem length. Depending on operator type the stem shall be designed to:
i. Transmit in compression a minimum of two times the rated output of a manual crank type gate actuator for manual crank type operators.
ii. Transmit in compression a minimum of 1.25 times the output thrust of an electric motor driven actuator in the stalled condition.
b. Stem threads shall be machine cut Acme type. The number of threads per inch and pitchshall be selected by the gate manufacturer to work most efficiently with the lift mechanism used and the gate speed specified.
c. A stop nut shall be furnished on the stem to limit the downward travel of the gate. The stop nut shall be fabricated from a single piece matching the stem material, tapped to match the stem, and drilled and tapped for a minimum of two 3/8 set screws.
2. The stem shall be connected to the top of the gate with a bolted connection designed to withstand the maximum design forces imposed by the operator under design head conditions. Connection shall be designed with a minimum safety factor of 2.
3. Stem guides, where required, to limit stem deflection shall be bronze or polymer bushed. Stem guides shall be factory aligned in self-contained gate frame applications and adjustable in the horizontal direction for non self-contained gate frame applications.
4. Furnish a bellows type stem protection boot for the entire length of the exposed stem from the top of the gate to the underside of the yoke or pedestal as applicable. The stem boot shall be reinforced to minimize contact between the boot and stem. The boot shall be furnished withnon metallic zipper running the full length of the boot to allow removal without disassembly of the gate/stem assembly.
5. Furnish a rigid protective cover for the stem section above the operator. The cover shall be made of clear butyrate plastic that will not discolor or become opaque for at least five years after installation. The cover shall be of sufficient diameter and length to permit full travel of the threaded stem without obstruction. The top of the stem cover shall be closed and vented. The bottom end of the stem cover shall be vented, drained, and mounted in a housing or adapter plate for easy field-mounting installation. The stem cover shall be graduated to allow for visual indication/determination of the gate position.
G. Anchor Bolts or Studs:
1. Gate Manufacturer shall furnish all anchor bolts and fasteners for the installation of the gate, frame, and operator assembly including but not limited to the following:
a. Gate frames
b. Stem guides
c. Operator pedestals
The Manufacturer shall be solely responsible for the size and number of anchor bolts to be used. The anchors shall be adequately sized and arranged as required to account for all static and dynamic loads imposed on the gate.
H. Dogging Slings:
1. The gates shall be supplied with two (2) dogging slings which are designed to facilitate removal of the gate operator with the slide in the fully open position. The dogging slings shall be minimum 3/8-inch, 6 x 37 classification with an independent wire rope core (IWRC), 316 stainless steel wire rope. Each dogging sling shall be capable of being shackled to a lifting bracket which is either welded to or integral to the slide. The lifting brackets shall be positioned on either side of the gate stem and shall not interfere with the operation of the gate or the gate position sensor indicator pointer rod. The opposing end of the dogging slings shall be shackled to an eyebolt and support plate which is welded to the top structural member of the self-contained gate frame. The shackles shall be min. 3/8-inch 316 stainless steel. The support plate and eyebolt shall be fabricated of 304L stainless steel.
1. Gate frame, yoke, slide, stem guides and miscellaneous fabrications: ASTM A276 and A240, Type 304L Stainless Steel
2. Seal backing bars: ASTM A276, Type 304L Stainless Steel
3. Stem: ASTM A276, Type 304L Stainless Steel
4. Stem Block (stem to gate connection): Bronze, ASTM B584
5. Fasteners and anchor bolts: ASTM F593 and F594 Type 316 Stainless Steel
6. Stem Boot: Nylon reinforced Goretex
7. Gasket material: EDPM
8. Slide Guides: Ultra high molecular weight polyethylene (UHMWPE) meeting the requirements of ASTM D4020
9. Bottom Seal Material: Resilient neoprene meeting the requirements of ASTM D-2000 grade 2 BC-510
10. Seals: Rubber J-type meeting the requirements of ASTM D2000 grade 2 BC 615 or fabricated from ultra high molecular weight polyethylene (UHMWPE) meeting the requirements of ASTM D4020
11. Stem Cover: Clear butyrate or polycarbonate
2.03 GATE OPERATORS: Each slide gate shall be supplied with an appropriately sized gate operator. The gate operator shall be sized and supplied by the gate Manufacturer for complete system responsibility. The Manufacturer shall provide gate operators as indicated herein.
A. Electric motor driven Operators:
1. Basic operator: The electric gate operator shall include the motor, reduction gearing, limit switch gearing, position limit switches, torque switches, declutch lever, drive nut, and handwheel as a self-contained unit and be mounted to the pedestal or yoke as applicable. The operator shall be capable of opening and closing the gate at a nominal speed of 6 inches per minute and the actuator shall also be capable of opening and closing the gate at intermittent positions.
2. Enclosure:
a. The gate actuator motor and all electrical enclosures shall have NEMA 4 and 6 ratings.Enclosures shall be constructed from cast iron with stainless steel external hardware.
b. Electrical Controls: The actuator shall be furnished with power and control terminal strips, limit switches, torque switches, all housed in a control compartment meeting NEMA 4 (watertight). The use of printed circuit boards as a substitute for interconnecting wiring inside of the operator is not acceptable. The enclosure shall have a bonded o-ring seal and a hinged cover. Cover bolting shall be captive stainless machinescrews.
3. Open-close service controls: The reversing contactor, pushbuttons, indicating lights, etc. shall be located within a NEMA 12 combination starter/control panel with separate NEMA 4X 316 stainless steel combination disconnect and push button station controls located adjacent to the actuator. See electrical drawings for the gate control schematic diagrams, front views, and component layout of the combination starter/control panel, and combination disconnect and push button station. The combination starter/control panel, and combination disconnect and push button station shall be built by a UL 508A panel builder per UL 508A standards and labeled accordingly per UL508A standards.
4. Motor: The motor shall be totally enclosed fan cooled (TEFC), C-face capacitor start induction run 208 VAC or 240 VAC per the electrical drawings and specifically designed for gate actuator service. Motor insulation shall be a minimum NEMA Class F, with a maximum continuous winding temperature rating of 190 degrees C (rise plus ambient) for the duty cycle specified. The motor shall be of sufficient capacity to open or close the gate at the maximum design head conditions and shall be capable of operating at plus or minus 10 percent of specified voltage. The motor duty rating shall be sufficient for one complete cycle, defined as opening the gate from a closed position to fully open and then returning to a fully closed position without exceeding its temperature rating. Motor bearings shall be of the anti-friction type, and permanently lubricated. The motor shall be an independent sub-assembly such that the power gearing shall not be an integral part of the motor assembly, to allow for motor or gear changes dictated by system operation requirements. The motor shall be equipped with internal thermalclass B contacts to protect against motor overload and 120 volt AC heaters.
5. Power Gearing: The actuator shall be a multiple reduction unit with power gearing consisting of spur, helical, or bevel gears, and worm gearing. The spur, helical, or bevel gearing and worm shall be of hardened alloy steel, and the worm gear shall be alloy bronze. All gearing shall be accurately cut. Non-metallic, aluminum or cast gearing shall not be allowed. Anti-friction bearings shall be used throughout.
6. Lubrication: All rotating power train components shall be immersed in grease with provisions for inspection and re-lubrication without disassembly. Lubricants shall be suitable for ambient conditions of minus 20 degrees Fahrenheit to 150 degrees Fahrenheit. Adequate seals shall be provided on all shafting.
7. Self-Locking Feature: Actuator gearing shall be self-locking.
8. Manual Operation: A metal hand wheel shall be provided for manual operation with an arrow to indicate “open” rotation. Manual operation of the Gates shall require no more than 40 pounds of force. The hand wheel shall not rotate during motor operation. An inoperative motor shall not prevent manual operation. When in the manual operating mode, the actuator will remain in this mode until the motor is energized, at which time the actuator will automatically return to electric operation. Movement from motor operation to hand wheel operation shall be accomplished by a positive padlockable declutch lever which mechanically disengages the motor and related gearing. It shall be impossible for simultaneous manual and motor operation to occur. Friction type declutch mechanism are not acceptable.
9. Stem Nut: The gate actuator shall have a removable stem nut or drive bushing of high tensile bronze or other material compatible with the stem material.
10. Position Limit Switches: Position limit switches shall be geared to the drive mechanism and in step with stem position whether operation is by the electric motor or manual hand crank. The associated gearing shall be an integral part of the operator. Limit switch gearing shall be made of bronze or stainless steel, grease lubricated, and totally enclosed to prevent dirt and foreign matter from entering the gear train. Switches shall be adjustable, allowing for trip points from fully open to fully closed positions of gate travel. They shall not be subject to breakage or slippage due to over-travel. Limit switch contacts shall be heavy duty, silver-plated with wiping action. The actuators shall have 2 NC and 2 NO switches for each end of travel position. Switch design shall permit visual verification of switch position without disassembly.
11. Torque Switch: Each gate actuator shall be equipped with a switch that will interrupt the control circuit in both the opening and closing directions when gate torque overload occurs or when gates require torque seating in the closed or open position. Four torque switches shall be furnished, two for each direction. The torque switches shall have graduated dials for both open and close directions of travel and each shall be independently adjustable, with a positive means to limit the adjustability so as not to exceed the actuator output torque capability. Switch design shall permit visible verification of switch position without disassembly.
12. Switch Contact Ratings: The position limit switch and torque switch shall be rated 240 volts, 5 amps continuous per NEMA standard ICS 2-125.
13. Stem Lubrication: Furnish an automated stem oiler with reservoir to lubricate both sections of the gate stem (above and below the drive nut). The oiler shall have a 1 quart min capacity with a120VAC solenoid valve electrically interlocked with operator motor. The stem oiler and/or drive nut shall be designed such that lubricating oil is distributed along the full length of the drive nut, ensuring that all threads from top to bottom, and regardless of the direction of stem travel, are lubricated. The lubricating system shall be capable of using 220 weight petroleum based lubricants. The oiler shall be manufactured by Essex Brass Model #377 or approved equivalent.
14. Position Indicator: Local position indication shall be provided by a dial window indicator located on the limit switch compartment cover, and labeled in 5% increments from 0 to 100% open.
15. Coating System: Surfaces shall be supplied with a protective coating system as specified in SECTION 09900.
PART 3 - EXECUTION
3.01 INSTALLATION:
A. Comply with provisions of AWWA C560, C540 and as specified.
B. Lubricate all bearings and gears before placing gates in operation.
C. Provide Manufacturer's field services as specified in DIVISION 1.
D. Perform equipment tests during and after start-up to determine if equipment is performing as specified.
1. For electric motor driven operators:
a. A Manufacturer’s field service technician shall perform the start up of the gate operator.
b. The technician shall accurately set the limit switches.
i. The lower limit shall be set to interrupt the control circuit when the slide firmly makes contact with the bottom seal but before the torque switch opens.
ii. The upper limit shall be set to interrupt the control circuit when the bottom of the gate clears the top seal.
c. The technician shall set the torque switch values to levels recommended by the gate Manufacturer.
