35_05_40.14_10_(Rev_2).pdf

New Cumber l and Hydr aul i c Syst em Upgr ade

SECTI ON TABLE OF CONTENTS

DI VI SI ON 35 - WATERWAY AND MARI NE CONSTRUCTI ON

SECTI ON 35 05 40. 14 10

HYDRAULI C POWER SYSTEMS FOR CI VI L WORKS STRUCTURES

PART 1 GENERAL

1. 1 SUMMARY

1. 2 REFERENCES

1. 3 DESI GN AND PERFORMANCE REQUI REMENTS

1. 3. 1 Desi gn Par amet er s

1. 4 SUBMI TTALS

1. 5 SCHEMATI C DRAWI NGS AND DATA

1. 5. 1 Shop Dr awi ngs

1. 5. 2 Fabr i cat i on Dr awi ngs

1. 5. 3 Hydr aul i c Power Uni t Dr awi ngs

1. 5. 4 Mani f ol d Dr awi ngs

1. 5. 5 Pi pi ng Dr awi ngs

1. 5. 6 El ect r i cal Dr awi ngs

1. 5. 7 Shop Assembl y Dr awi ngs

1. 5. 8 Hydr aul i c Schemat i c

1. 5. 9 Pr oduct Dat a

1. 5. 10 Del i ver y Dr awi ngs

1. 5. 11 Shop Assembl y and Test i ng Pr ocedur es and Resul t s

1. 5. 12 Fi el d I nst al l at i on Pr ocedur es

1. 5. 13 Desi gn and Per f or mance Requi r ement s

1. 5. 14 Cl eani ng and Fl ushi ng Pr ocedur es and Resul t s

1. 5. 15 Er ect i ng Engi neer Qual i f i cat i ons

1. 6 DELI VERY, STORAGE, AND HANDLI NG

1. 6. 1 Packagi ng

1. 6. 2 Shi ppi ng, Pr eser vat i on, and St or age

1. 7 WARRANTY

1. 8 QUALI TY CONTROL

PART 2 PRODUCTS

2. 1 MATERI ALS AND MECHANI CAL EQUI PMENT

2. 1. 1 Gener al

2. 2 HYDRAULI C POWER UNI TS

2. 2. 1 Mot or s

2. 2. 2 Mot or Coupl i ng

2. 2. 3 Pump

2. 2. 4 Pr essur e Rel i ef and Vent Val ve

2. 2. 5 Check Val ve

2. 2. 6 Power Uni t Val ve Mani f ol d

2. 2. 7 Pr essur e Gauge and Shut of f Val ve

2. 2. 8 Hydr aul i c Power Uni t Pi pi ng

2. 2. 9 Oi l St or age Tank

2. 2. 10 Top Cl eanout and Cover

2. 2. 11 Oi l Level Si ght Gauge

2. 2. 12 Tank Dr ai n

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2. 2. 13 Magnet i c Separ at or s

2. 2. 14 Fl ow Swi t ch

2. 2. 15 Reser voi r Heat er wi t h I nt egr al Ther most at and Swi t ch

2. 2. 16 Hi gh Temper at ur e Swi t ch

2. 2. 17 Level Swi t ches

2. 2. 17. 1 Reser voi r Tank Level

2. 2. 17. 2 Dr i p Pan

2. 2. 18 Reser voi r I sol at or

2. 2. 19 I sol at or Pi pi ng

2. 2. 20 Pr essur e Rel i ef and Emer gency Vent i ng

2. 2. 21 Pr essur e Swi t ches

2. 2. 22 Pr essur e Gauges and Snubber s

2. 2. 23 Pr essur e Fi l t er

2. 2. 24 Ret ur n Fi l t er

2. 2. 25 Cont r ol Cabi net

2. 3 MANI FOLDS

2. 3. 1 Gener al

2. 3. 2 Mi t er Gat e Mani f ol d Val v i ng

2. 3. 3 Pi pe Mani f ol d Component s

2. 4 PI PE AND FI TTI NGS

2. 5 HOSE AND FI TTI NGS

2. 6 PI PE AND TUBE HANGERS AND SUPPORTS

2. 7 FLANGES

2. 8 SHUT- OFF VALVES

2. 9 SPARE PARTS

2. 10 HYDRAULI C OI L

2. 11 PORTABLE PUMP AND MOTOR UNI T

2. 12 ELECTRI CAL EQUI PMENT

2. 12. 1 Condui t , Duct , and Accessor i es

2. 12. 1. 1 Ri gi d Met al Condui t

2. 12. 1. 2 Condui t Fi t t i ngs

2. 12. 1. 3 Condui t and Cabi net Suppor t s

2. 12. 2 Cabi net s and Boxes

2. 12. 3 Pump Mot or s

2. 12. 3. 1 Rat i ng

2. 12. 3. 2 Wi ndi ng I nsul at i on

2. 12. 3. 3 Wi ndi ng Heat er s

2. 12. 3. 4 Ter mi nal Leads

2. 12. 4 Cont r ol Component s

2. 12. 4. 1 Cont r ol Devi ces and Wi r i ng

2. 12. 4. 2 Pr essur e Swi t ches

2. 12. 4. 3 Pr essur e Tr ansducer s

2. 12. 4. 4 Fl ow Det ect i on Swi t ches

2. 13 SHOP ASSEMBLY AND TESTI NG

2. 13. 1 Shop Test s of Hydr aul i c Power Uni t s

2. 13. 2 Shop Test s of Mani f ol ds

2. 14 MANUFACTURER PREPARATI ON BEFORE SHI PMENT

2. 14. 1 Fl ushi ng Hydr aul i c Power Uni t

2. 15 PAI NTI NG

2. 15. 1 Cl eani ng And Pr epar at i on Of Sur f aces To Be Pai nt ed

2. 15. 1. 1 Gener al Requi r ement s

2. 15. 1. 2 Fer r ous Sur f aces Exposed t o At mospher e

2. 15. 2 Pai nt Appl i cat i on

2. 15. 2. 1 Gener al

2. 15. 2. 2 Mi xi ng and Thi nni ng

2. 15. 2. 3 At mospher i c and Sur f ace Condi t i ons

2. 15. 2. 4 Ti me Bet ween Sur f ace Pr epar at i on and Pai nt i ng

2. 15. 2. 5 Met hod of Pai nt Appl i cat i on

2. 15. 2. 6 Cover age and Fi l m Thi ckness

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2. 15. 2. 6. 1 Measur ement on Fer r ous Met al

2. 15. 2. 7 Pr ogr ess of Pai nt i ng Wor k

2. 15. 2. 8 Pr ot ect i on of Pai nt ed Sur f aces

2. 15. 3 Pai nt Syst ems Appl i cat i on

2. 15. 3. 1 Sur f ace Pr epar at i on

2. 15. 3. 2 Syst em No. 23- D

2. 15. 4 Pai nt i ng Schedul e

2. 15. 4. 1 Fi ni sh Col or s

PART 3 EXECUTI ON

3. 1 EXAMI NATI ON

3. 2 I NSTALLATI ON

3. 3 POWER PI PI NG

3. 3. 1 Pi pi ng I nst al l at i on

3. 3. 2 Pi pi ng Vent s and Dr ai ns

3. 3. 3 Mount i ng Suppor t f or Reser voi r I sol at or and Mani f ol ds

3. 3. 4 I dent i f i cat i on of Pi pi ng and Val ves

3. 4 CLEANI NG AND FLUSHI NG

3. 4. 1 Fl ushi ng Pi pi ng

3. 4. 2 Fl ushi ng Mani f ol ds and Hoses

3. 5 FI LLI NG AND BLEEDI NG THE SYSTEM

3. 6 ERECTI ON ENGI NEER

3. 7 FI ELD TESTS AND I NSPECTI ONS

3. 7. 1 Fi el d Test i ng

3. 7. 2 Pi pe Pr essur e Test

3. 7. 3 Fi nal Accept ance Test s

3. 7. 3. 1 I ni t i al St ar t - Up

3. 7. 3. 2 Combi ned Syst em Test s

3. 7. 3. 3 Test Repor t s

3. 8 CLEAN- UP

3. 9 OPERATI ON AND MAI NTENANCE

3. 10 TRAI NI NG

3. 10. 1 Gener al

3. 10. 2 Fi el d Tr ai ni ng

- - End of Sect i on Tabl e of Cont ent s - -

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SECTI ON 35 05 40. 14 10

HYDRAULI C POWER SYSTEMS FOR CI VI L WORKS STRUCTURES

PART 1 GENERAL

1. 1 SUMMARY

The wor k cover ed by t hi s sect i on of t he speci f i cat i ons consi st s of det ai l ed r equi r ement s f or t he desi gn, f abr i cat i on, shop assembl y, t est i ng, del i ver y, and i nst al l at i on of t he hydr aul i c power syst ems f or oper at i on of t he mi t er gat es and cul ver t t ai nt er val ves as speci f i ed and as shown. The Cont r act or shal l f ur ni sh al l pl ant , l abor , mat er i al and equi pment f or t he const r uct i on, shop t est i ng, i nst al l at i on and f i el d t est i ng of a compl et e hydr aul i c syst em f or t he mai n l ock chamber . The syst em shal l be desi gned t o oper at e t he hydr aul i c cyl i nder s on t he mi t er gat e machi ner y and cul ver t val ve machi ner y as shown on t he dr awi ngs and speci f i ed her ei n. The syst em shal l i ncl ude hydr aul i c power uni t s compl et e wi t h al l pi pi ng, pi pe f i t t i ngs, hose, hose f i t t i ngs, hanger s and suppor t s, val ves, cont r ol val ves and mani f ol ds, and ot her i t ems as shal l be necessar y f or a compl et e syst em f or t he l ock. Compl et e oper at i ng and mai nt enance i nst r uct i ons shal l be pr ovi ded as her ei naf t er speci f i ed. Shop dr awi ngs shal l be submi t t ed f or appr oval as her ei naf t er descr i bed. The hydr aul i c syst em shal l be sui t abl e f or mai nt ai ni ng an oper at i ng pr essur e of 1000 pounds per squar e i nch at each hydr aul i c power uni t ( HPU) . The l ayout of t he syst em shal l be as shown on t he dr awi ngs. Al l val ves of t he same t ype and si ze shal l be t he pr oduct of a s i ngl e manuf act ur er . Shoul d t her e be any necessi t y f or r ear r angement of t he pi pi ng, f i t t i ngs, or equi pment due t o f i el d condi t i ons or ot her causes, t he Cont r act or shal l submi t det ai l s of any pr oposed changes t o t he Cont r act i ng Of f i cer f or appr oval . Wher e i mpr ovement s t o t he hydr aul i c syst em desi gn can be made, consi der at i on wi l l be gi ven by t he Gover nment . Consi der at i on may be gi ven f or no cost var i at i ons submi t t ed f or appr oval wher e pr act i cal and sui t abl e wi t h r egar d t o machi ner y component s i ndi cat ed on t he dr awi ngs. Any and al l changes shal l be subj ect t o t he appr oval of t he Gover nment .

1. 2 REFERENCES

The publ i cat i ons l i s t ed bel ow f or m a par t of t hi s speci f i cat i on t o t he ext ent r ef er enced. The publ i cat i ons ar e r ef er r ed t o wi t hi n t he t ext by t he basi c desi gnat i on onl y.

ASME I NTERNATI ONAL ( ASME)

ASME B16. 11 ( 2016) For ged Fi t t i ngs, Socket - Wel di ng and Threaded

ASME B31. 1 ( 2016; Er r at a 2016) Power Pi pi ng

ASME B36. 19M ( 2004; R 2015) St ai nl ess St eel Pi pe

ASME B40. 100 ( 2013) Pr essur e Gauges and Gauge Attachments

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ASTM I NTERNATI ONAL ( ASTM)

ASTM A182/ A182M ( 2017) St andar d Speci f i cat i on f or For ged or Rol l ed Al l oy and St ai nl ess St eel Pi pe Fl anges, For ged Fi t t i ngs, and Val ves and Par t s f or Hi gh- Temper at ur e Ser vi ce

ASTM A312/ A312M ( 2017) St andar d Speci f i cat i on f or Seaml ess, Wel ded, and Heavi l y Col d Wor ked Aust eni t i c St ai nl ess St eel Pi pes

ASTM D3951 ( 2015) Commer ci al Packagi ng

I NSTI TUTE OF ELECTRI CAL AND ELECTRONI CS ENGI NEERS ( I EEE)

I EEE C57. 12. 70 ( 2011) St andar d Ter mi nal Mar ki ngs and Connect i ons f or Di st r i but i on and Power Transformers

I NTERNATI ONAL ORGANI ZATI ON FOR STANDARDI ZATI ON ( I SO)

I SO 1219- 1 ( 2012; Amd 1 2016) Fl ui d Power Syst ems and Component s Gr aphi c Symbol s and Ci r cui t Di agr ams - Par t 1: Gr aphi c Symbol s f or Convent i onal Use and Dat a- Pr ocessi ng Applications

I SO 1219- 2 ( 2012) Fl ui d Power Syst ems and Component s Gr aphi c Symbol s and Ci r cui t Di agr ams - Par t 2: Ci r cui t Di agr ams

I SO 4021 ( 1992) Hydr aul i c Fl ui d Power - Par t i cul at e Cont ami nat i on Anal ysi s - Ext r act i on of Fl ui d Sampl es f r om Li nes of an Oper at i ng System

I SO 4406 ( 2017) Hydr aul i c Fl ui d Power - Fl ui ds - Met hod f or Codi ng t he Level of Cont ami nat i on by Sol i d Par t i c l es

I SO 4407 ( 2002) Hydr aul i c Fl ui d Power - Fl ui d Cont ami nat i on - Det er mi nat i on of Par t i cul at e Cont ami nat i on by t he Count i ng Met hod Usi ng an Opt i cal Mi cr oscope

I SO 4413 ( 2010) Hydr aul i c Fl ui d Power — Gener al Rul es and Saf et y Requi r ement s f or Syst ems and Thei r Component s

MANUFACTURERS STANDARDI ZATI ON SOCI ETY OF THE VALVE AND FI TTI NGS

I NDUSTRY ( MSS)

MSS SP- 58 ( 1993; Reaf f i r med 2010) Pi pe Hanger s and Suppor t s - Mat er i al s, Desi gn and Manuf act ur e, Sel ect i on, Appl i cat i on, and Installation

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NATI ONAL ELECTRI CAL MANUFACTURERS ASSOCI ATI ON ( NEMA)

ANSI C80. 1 ( 2005) Amer i can Nat i onal St andar d f or El ect r i cal Ri gi d St eel Condui t ( ERSC)

NEMA I CS 2 ( 2000; R 2005; Er r at a 2008) I ndust r i al Cont r ol and Syst ems Cont r ol l er s, Cont act or s, and Over l oad Rel ays Rat ed 600 V

NEMA MG 1 ( 2016; SUPP 2016) Mot or s and Gener at or s

SOCI ETY OF AUTOMOTI VE ENGI NEERS I NTERNATI ONAL ( SAE)

SAE J517 ( 2017) Hydr aul i c Hose

SAE J518- 1 ( 2013) Hydr aul i c Fl anged Tube, Pi pe, and Hose Connect i ons, 4- Scr ew Fl ange Connect i on Par t 1: 3. 5 MPa t o 35 MPa ( Code 61)

UNDERWRI TERS LABORATORI ES ( UL)

UL 50 ( 2015) UL St andar d f or Saf et y Encl osur es f or El ect r i cal Equi pment , Non- Envi r onment al Consi der at i ons

UL 6 ( 2007; Repr i nt Nov 2014) El ect r i cal Ri gi d Met al Condui t - St eel

1. 3 DESI GN AND PERFORMANCE REQUI REMENTS

The cont r act dr awi ngs i ndi cat e t he gener al ar r angement of t he hydr aul i c power syst em f or oper at i on of t he mai n chamber mi t er gat es and cul ver t t ai nt er val ves, c l ear ances necessi t at ed by t he st r uct ur e or ot her equi pment , maxi mum over al l di mensi ons, and ot her per t i nent f eat ur es.

Fur ni sh t he det ai l ed desi gn i n conf or mi t y wi t h t he f ol l owi ng desi gn cr i t er i a. Fur ni sh t he det ai l ed desi gn i n conf or mi t y wi t h I SO 4413, and t he f ol l owi ng desi gn cr i t er i a. I dent i f y desi gn and di mensi onal changes necessar y t o sat i sf y t he pr i nci pal desi gn par amet er s i dent i f i ed i n t he par agr aph DESI GN PARAMETERS ( bel ow) as var i at i ons i n t he submi t t al s.

Di mensi ons submi t t ed t hat di f f er f r om t hose i ndi cat ed and not ot her wi se const r ai ned by t he Desi gn Par amet er s and physi cal l i mi t at i ons of i nst al l at i on ar e subj ect t o appr oval . Al so submi t desi gn comput at i ons f or al l ext ensi on of desi gn i t ems.

1. 3. 1 Desi gn Par amet er s

The pr i nci pal desi gn par amet er s f or t he hydr aul i c power syst em ar e as f ol l ows and wer e devel oped at t he mi ni mum oper at i ng t emper at ur e and ut i l i z i ng t he hydr aul i c f l ui d as speci f i ed: AW 32 oper at i ng at 50 degr ees F.

1. 4 SUBMITTALS

Gover nment appr oval i s r equi r ed f or submi t t al s wi t h a " G" desi gnat i on;

submi t t al s not havi ng a " G" desi gnat i on ar e f or i nf or mat i on onl y. When used, a desi gnat i on f ol l owi ng t he " G" desi gnat i on i dent i f i es t he of f i ce t hat wi l l r evi ew t he submi t t al f or t he Gover nment . Submi t t he f ol l owi ng i n accor dance wi t h Sect i on 01 33 00 SUBMI TTAL PROCEDURES:

SECTI ON 35 05 40. 14 10 Page 6

SD- 02 Shop Dr awi ngs

Schemat i c Dr awi ngs And Dat a

( 1) Engi neer i ng dat a i ncl udi ng per f or mance dat a and cur ves f or pumps, mot or s, val ves and f i l t er s.

( 2) Engi neer i ng dat a f or hydr aul i c power uni t showi ng gener al ar r angement of component s and out l i ne di mensi ons of uni t wi t h di mensi ons l ocat i ng al l por t s and t he uni t wei ght . Al l component s shal l be i dent i f i ed on t he dr awi ngs and suf f i c i ent i nf or mat i on pr ovi ded t o det er mi ne whet her t he component s pr oposed conf or ms t o t he speci f i cat i ons. Layout and ar r angement dr awi ngs shal l be t o scale.

( 3) Engi neer i ng dat a f or mani f ol ds showi ng t he gener al ar r angement of component s, out l i ne di mensi ons, l ocat i on of al l por t s and pr ovi s i ons f or mount i ng. Al l component s shal l be i dent i f i ed on t he dr awi ngs and suf f i c i ent i nf or mat i on pr ovi ded t o det er mi ne whet her t he component s pr oposed conf or ms t o t he speci f i cat i ons.

Al l por t conf i gur at i ons and connect i ons shal l be i dent i f i ed.

( 4) Cat al og cut s and out l i ne di mensi ons f or t he pumps, mot or s, shaf t coupl i ngs, f i l t er s, heat er s, t her most at s, f l oat swi t ches, f l exi bl e r eser voi r br eat her s, hose, hose f i t t i ngs, cont r ol val ves, needl e val ves and shut of f val ves and ot her accessor i es.

( 5) Pi pi ng di agr ams showi ng t he compl et e hydr aul i c syst em i dent i f y i ng al l i t ems of equi pment i ncor por at ed i n t he syst em.

( 6) Scal e dr awi ngs of i nst al l at i on, 1- 1/ 2" = 1' - 0" or l ar ger scal e, of power uni t s i n machi ne r ooms, mani f ol ds i n machi ner y r ecesses and pi pi ng i n gal l er i es i n pl an and el evat i on. Addi t i onal dr awi ngs shal l be pr ovi ded, 1- 1/ 2" = 1' - 0" or l ar ger scal e, showi ng al l pi pi ng, val ves, f i t t i ngs, pet cocks f or vent s and dr ai ns and suppor t s i n pl ans and el evat i ons.

( 7) Shop dr awi ngs showi ng det ai l s of al l pi pe suppor t s i ncl udi ng t hose f or mani f ol ds and on t he hydr aul i c power uni t .

( 8) Cat al og cut s and el ect r i cal dr awi ngs of al l el ect r i cal equi pment associ at ed wi t h t he Hydr aul i c power uni t . El ect r i cal dr awi ngs shal l i ncl ude compl et e schemat i c di agr ams and connect i on di agr ams and dr awi ngs showi ng t he ar r angement of component s on t he door and i nt er i or of t he cabi net . Connect i on di agr ams shal l show el ect r i cal connect i ons ( by l i nes) f or each conduct or bet ween t er mi nal poi nt s. Al l t er mi nal poi nt s shal l be i dent i f i ed.

( 9) Pr ocedur es f or al l shop and f i el d t est i ng and f or f l ushi ng t he compl et e hydr aul i c syst em.

( 10) Test r epor t s of t he r esul t s of al l shop and f i el d t est i ng and of t he hydr aul i c syst em f l ushi ng i ncl udi ng t est r epor t s on t he cl eanl i ness of t he oi l used t o f i l l t he syst em.

SD- 03 Pr oduct Dat a

Hydr aul i c Power Uni t s; G, DO

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Hydr aul i c Oi l ; G, DO

Mat er i al s and Mechani cal Equi pment

St andar d Pr oduct s; G, DO

El ect r i cal Equi pment

Desi gn and Per f or mance Requi r ement s; G, DO

Shop Assembl y and Test i ng Pr ocedur es

I nst al l at i on Pr ocedur es; G, DO

Pi pi ng I nst al l at i on

Er ect i ng Engi neer Qual i f i cat i ons; G, RO

Cl eani ng and Fl ushi ng

Fi el d Test i ng

SD- 06 Test Repor t s

Oper at i onal Test Repor t s

Shop Test s

Fi el d Test s

SD- 10 Oper at i on and Mai nt enance Dat a

Oper at i on and Mai nt enance; G, DO

Si x compl et e set s of appr oved i nst r uct i ons cont ai ni ng t he manuf act ur er ' s oper at i ng and mai nt enance i nst r uct i ons f or each pi ece of equi pment shal l be f ur ni shed. Each set shal l be assembl ed, i ndexed and bound i n a pr oper l y l abel ed t hr ee r i ng bi nder wi t h a dur abl e cover . One compl et e set shal l be submi t t ed f or appr oval at t he t i me t he t est pr ocedur e i s submi t t ed, and t he r emai ni ng set s shal l be f ur ni shed bef or e t he cont r act i s compl et ed. I n addi t i on t o t he s i x har dcopy set s, one compl et e set of t he oper at i ng and mai nt enance i nst r uct i ons shal l be f ur ni shed i n el ect r oni c " . pdf " f or mat upon compl et i on of t he l ock oper at i ng machi ner y. The f ol l owi ng i dent i f i cat i on shal l be i nscr i bed on t he cover s: t he wor ds " NEW CUMBERLAND LOCK - MAI N CHAMBER LOCK HYDRAULI C SYSTEM OPERATI NG AND MAI NTENANCE I NSTRUCTI ONS" , t he name of t he Cont r act or , and t he cont r act number . Fl ysheet s shal l be pl aced bef or e i nst r uct i ons cover i ng each subj ect . The i nst r uct i on sheet s shal l be appr oxi mat el y 8- 1/ 2 by 11 i nches, wi t h l ar ge sheet s of dr awi ngs f ol ded i n. The i nst r uct i ons shal l i ncl ude, but not be l i mi t ed t o, t he f ol l owi ng:

( 1) Appr oved syst em l ayout showi ng hydr aul i c power uni t s, pi pi ng, mani f ol ds and val ves

( 2) Appr oved det ai l ed dr awi ngs of power uni t s and schemat i cs wi t h al l

SECTI ON 35 05 40. 14 10 Page 8 component s i dent i f i ed

( 3) Appr oved det ai l ed dr awi ngs of mani f ol ds and schemat i cs wi t h al l component s i dent i f i ed

( 4) Appr oved wi r i ng and cont r ol di agr ams and panel l ayout s

( 5) A cont r ol sequence descr i bi ng st ar t up, oper at i on, and shut down

( 6) Oper at i ng and mai nt enance i nst r uct i ons f or each pi ece of equi pment , i ncl udi ng l ubr i cat i on i nst r uct i ons

( 7) Manuf act ur er ' s bul l et i ns, cut s, and descr i pt i ve dat a

( 8) Par t s l i s t s and r ecommended spar e par t s

Upon compl et i on of t he wor k and at a t i me desi gnat ed by t he Cont r act i ng Of f i cer , t he ser vi ces of one or mor e compet ent engi neer s shal l be pr ovi ded by t he Cont r act or f or a per i od of not l ess t han one day t o i nst r uct r epr esent at i ves of t he Gover nment i n t he oper at i on and mai nt enance of t he syst em. These f i l ed i nst r uct i ons shal l cover al l i t ems cont ai ned i n t he bound instructions.

1. 5 SCHEMATI C DRAWI NGS AND DATA

1. 5. 1 Shop Dr awi ngs

I ncl ude f abr i cat i on, shop assembl y, del i ver y, and f i el d i nst al l at i on dr awi ngs i n t he det ai l ed shop dr awi ngs. Det ai l any component par t of f abr i cat ed i t ems omi t t ed on t he shop dr awi ngs. I f depar t ur es f r om t he cont r act dr awi ngs ar e deemed necessar y by t he Cont r act or , submi t det ai l s of such depar t ur es, i ncl udi ng changes i n r el at ed por t i ons of t he pr oj ect and r easons t her eof , wi t h t he shop dr awi ngs. Pr ovi de f abr i cat i on and assembl y dr awi ngs t o 1: 8 1- 1/ 2 i nch = 1 f oot - 0 i nch or l ar ger scal e.

1. 5. 2 Fabr i cat i on Dr awi ngs

Pr ovi de f abr i cat i on dr awi ngs f or al l mechani cal and st r uct ur al par t s or component s, except t hose whi ch ar e of st andar d manuf act ur e. The dr awi ngs must show compl et e det ai l s of mat er i al s, t ol er ances, machi ned sur f ace f i ni shes, connect i ons, and pr oposed wel di ng sequences whi ch di f f er ent i at e shop wel ds and f i el d wel ds. Pr ovi de det ai l ed dr awi ngs of t he dr i l l ed passages or t he mani f ol ds.

1. 5. 3 Hydr aul i c Power Uni t Dr awi ngs

Pr ovi de dr awi ngs f or hydr aul i c power uni t s showi ng gener al ar r angement of component s and out l i ne di mensi ons of uni t . I dent i f y al l component s on t he dr awi ngs and pr ovi de suf f i c i ent i nf or mat i on t o det er mi ne whet her t he component s pr oposed conf or m t o t he speci f i cat i ons.

1. 5. 4 Mani f ol d Dr awi ngs

Pr ovi de f abr i cat i on dr awi ngs f or al l mani f ol ds showi ng gener al ar r angement s out l i ne di mensi ons, and dr i l l i ng di mensi ons. I dent i f y al l component s on t he dr awi ngs and pr ovi de suf f i c i ent i nf or mat i on t o det er mi ne whet her t he component s pr oposed conf or m t o t he speci f i cat i ons. I dent i f y al l por t conf i gur at i ons and connect i ons.

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1. 5. 5 Pi pi ng Dr awi ngs

Pr ovi de pi pi ng dr awi ngs showi ng t he compl et e hydr aul i c syst em i n schemat i c f or mat i dent i f y i ng al l i t ems of equi pment i ncor por at ed i n t he syst em.

I ncl ude det ai l s of al l pi pe suppor t s i ncl udi ng t hose f or mani f ol ds and on t he hydr aul i c power uni t .

1. 5. 6 El ect r i cal Dr awi ngs

Pr ovi de el ect r i cal dr awi ngs of al l el ect r i cal equi pment . On el ect r i cal dr awi ngs i ncl ude compl et e schemat i c di agr ams and connect i on di agr ams. On connect i on di agr ams show el ect r i cal connect i ons ( by l i nes) f or each conduct or bet ween t er mi nal poi nt s. I dent i f y t er mi nal poi nt s.

1. 5. 7 Shop Assembl y Dr awi ngs

Pr ovi de shop assembl y dr awi ngs wi t h det ai l s f or connect i ng t he adj oi ni ng f abr i cat ed component s i n t he shop t o ensur e sat i sf act or y f i el d installation.

1. 5. 8 Hydr aul i c Schemat i c

Pr ovi de a compl et e hydr aul i c schemat i c i n accor dance wi t h I SO 1219- 1 and I SO 1219- 2. Show al l hydr aul i c component s on t he schemat i c, and i ndi cat e al l set poi nt and si ze par amet er s f or each component .

1. 5. 9 Pr oduct Dat a

I ncl ude per f or mance dat a and cur ves f or pumps, mot or s and val ves. Pr ovi de cat al og cut s and out l i ne di mensi ons f or t he pumps, mot or s, f i l t er s, heat er s, t her most at s, f l oat swi t ches, pr essur e t r ansducer , swi t ches, and al l val ves, val ve cont r ol s and ot her accessor i es.

1. 5. 10 Del i ver y Dr awi ngs

Pr ovi de del i ver y dr awi ngs wi t h descr i pt i ons of met hods of del i ver i ng component s t o t he s i t e, i ncl udi ng det ai l s f or suppor t i ng f abr i cat ed component s dur i ng shi ppi ng t o pr event di st or t i on or ot her damage.

1. 5. 11 Shop Assembl y and Test i ng Pr ocedur es and Resul t s

Pr ovi de pr ocedur es f or shop t est i ng and oper at i ng t est f or al l t est i ng out l i ned i n par agr aphs SHOP ASSEMBLY AND TESTI NG and FI ELD TESTS AND I NSPECTI ONS. Submi t oper at i onal t est r epor t s f or al l r equi r ed shop t est i ng and t est i ng of equi pment af t er i nst al l at i on. Pr ovi de r ecor ds of al l adj ust ment s and f i nal set t i ngs f or al l hydr aul i c component s i n t he syst em. Thi s i ncl udes pump f l ow r at es, oper at i ng t i mes, r el i ef set t i ngs, val ve adj ust ment s, oper at i ng pr essur es at bot h t he hydr aul i c power uni t s and cyl i nder mani f ol ds, f l ow l evel adj ust ment s, f i l t er di f f er ent i al swi t ch set t i ngs, and ot her par amet er s as out l i ned i n t he par agr aph TEST REPORTS.

1. 5. 12 Fi el d I nst al l at i on Pr ocedur es

Pr ovi de f i el d i nst al l at i on dr awi ngs wi t h a det ai l ed descr i pt i on of t he f i el d i nst al l at i on pr ocedur es. I ncl ude t he l ocat i on and met hod of suppor t of i nst al l at i on and handl i ng equi pment , t he pr ovi s i ons t o be t aken t o pr ot ect concr et e and ot her wor k dur i ng i nst al l at i on, t he met hod of mai nt ai ni ng component s i n cor r ect al i gnment , and t he met hods f or

SECTI ON 35 05 40. 14 10 Page 10 i nst al l i ng ot her appur t enant i t ems. I ncl ude dat es and schedul e of wor k.

Submi t met hods and pr ocedur es t o accel er at e t he sequence of wor k f or approval.

1. 5. 13 Desi gn and Per f or mance Requi r ement s

Pr ovi de desi gn comput at i ons f or al l i t ems whi ch ar e desi gned by t he Contractor.

1. 5. 14 Cl eani ng and Fl ushi ng Pr ocedur es and Resul t s

Pr ovi de det ai l ed pr ocedur e f or t he c l eani ng and f l ushi ng of hydr aul i c cyl i nder s, pi pi ng, and power uni t as out l i ned i n par agr aph CLEANI NG AND FLUSHI NG, not l ess t han 30 days bef or e st ar t of oper at i ons. Pr ovi de t est r epor t s of t he r esul t s of t he f l ushi ng and of t he oi l used t o f i l l t he system.

1. 5. 15 Er ect i ng Engi neer Qual i f i cat i ons

Pr ovi de a r esume f or t he on- si t e er ect i ng engi neer wi t h det ai l s on exper i ence and backgr ound i n s i mi l ar i nst al l at i ons.

1. 6 DELI VERY, STORAGE, AND HANDLI NG

1. 6. 1 Packaging

Do not pr epar e t he hydr aul i c power syst ems f or shi pment unt i l t hey have been i nspect ed and accept ed f or shi pment at or i gi n by t he Cont r act i ng Of f i cer , unl ess i nspect i on has been wai ved i n wr i t i ng. Shi p each hydr aul i c power syst em or subassembl y compl et el y assembl ed. The subassembl i es ar e def i ned as t he f ol l owi ng:

a. Hydr aul i c power uni t s

b. Pi pi ng assembl i es

c. Cont r ol consol es

Pr ovi de t he subassembl i es wi t h adequat e pr ot ect i ve pads, suppor t s, and bl ocki ng and secur el y r est r ai ned t o pr event di st or t i on or damage t o t he pai nt ed sur f aces i n t r ansi t . Any l oss or damage dur i ng shi pment , i ncl udi ng damage t o t he pai nt ed sur f aces, i s t he Cont r act or ' s r esponsi bi l i t y ; r epl ace or r epai r wi t hout cost t o t he Gover nment . Pack al l accessor i es and spar e par t s separ at el y i n cont ai ner s pl ai nl y mar ked " ACCESSORI ES ONLY, " or " SPARE PARTS ONLY. " Pl ace a packi ng l i s t , l i s t i ng t he cont ent s of each cont ai ner , i n a moi st ur e- pr oof envel ope and secur el y f ast en t o t he out si de of t he cont ai ner . St andar d commer ci al packagi ng i n accor dance wi t h ASTM D3951 wi l l be accept abl e except wher e a di f f er ent met hod or st andar d of packagi ng i s speci f i ed.

1. 6. 2 Shi ppi ng, Pr eser vat i on, and St or age

Packi ng, cr at i ng, cr adl es, et c. , necessar y t o ensur e saf e shi pment ar e t he r esponsi bi l i t y of t he Cont r act or and become t he pr oper t y of t he Gover nment upon del i ver y of t he equi pment . Pr ot ect equi pment del i ver ed and pl aced i n st or age f r om t he weat her , humi di t y, t emper at ur e var i at i on, di r t and dust , or ot her cont ami nant s.

SECTI ON 35 05 40. 14 10 Page 11

1. 7 WARRANTY

Al l equi pment must be guar ant eed f or a per i od of 2 year s f r om t he dat e of accept ance. Guar ant ee r epl acement par t s f or 2 year s f r om dat e of r epl acement . Pr ovi de War r ant y agai nst def ect i ve mat er i al s, desi gn, and wor kmanshi p. I n cases wher e t he equi pment manuf act ur er ' s adver t i sed mi ni mum guar ant ee i s i n excess of 2 year s, i t r emai ns i n f or ce f or i t s f ul l per i od. Upon r ecei pt of not i ce f r om t he Gover nment of f ai l ur e of any of t he par t s dur i ng t he war r ant y per i od, pr ovi de new r epl acement par t s pr ompt l y at no addi t i onal cost t o t he Gover nment .

1. 8 QUALI TY CONTROL

Est abl i sh and mai nt ai n qual i t y cont r ol f or oper at i ons under t hi s sect i on t o assur e compl i ance wi t h cont r act r equi r ement s and mai nt ai n r ecor ds of qual i t y cont r ol f or al l mat er i al s, f abr i cat ed par t s, equi pment , and const r uct i on oper at i ons. I n addi t i on, est abl i sh and mai nt ai n sur vei l l ance f or qual i t y cont r ol over sub- cont r act or s, suppl i er s, or manuf act ur er s. The qual i t y cont r ol must i ncl ude a mi ni mum of t wo shop i nspect i ons dur i ng manuf act ur e and assembl y of t he hydr aul i c power uni t s and mani f ol ds. The qual i t y cont r ol i ncl udes but i s not be l i mi t ed t o t he following:

a. Mat er i al s and wor kmanshi p.

b. Manuf act ur e and i nst al l at i on of t he pi pi ng, hydr aul i c power uni t s and mani f ol ds, compl et e.

c. Cl eani ng and f l ushi ng.

d. Shop assembl y and t est s.

e. Fi el d er ect i on and t est s.

f . Damage and def ect s.

Fur ni sh a copy of t hese r ecor ds and t est s, as wel l as t he r ecor ds of cor r ect i ve act i on t aken, t o t he Gover nment .

PART 2 PRODUCTS

2. 1 MATERI ALS AND MECHANI CAL EQUI PMENT

2. 1. 1 General

Pr ovi de mat er i al s and mechani cal equi pment t hat conf or m t o t he r equi r ement s i ndi cat ed or speci f i ed, and i f not speci f i ed, f ur ni sh mat er i al s and mechani cal equi pment of t he best commer ci al gr ade qual i t y sui t ed t o t he i nt ended use and as appr oved. Al l el ect r i c mot or s, hydr aul i c pumps, val ves and si mi l ar i t ems and/ or accessor i es, of t he same t ype and si ze, must be t he pr oduct s of t he same manuf act ur er , unl ess ot her wi se appr oved. Per manent l y di spl ay t he manuf act ur er ' s name, addr ess, and cat al og number on a namepl at e secur el y at t ached t o each maj or i t em of equipment.

Submi t dat a speci f i cat i ons and assembl y dr awi ngs showi ng si zes, r at i ngs, par t s and mat er i al l i s t s, over al l di mensi ons, and mount i ng di mensi ons wi t h t he pr oduct dat a.

SECTI ON 35 05 40. 14 10 Page 12

2. 2 HYDRAULI C POWER UNI TS

Four hydr aul i c power uni t s shal l be f ur ni shed and i nst al l ed f or each mi t er gat e and cul ver t val ve combi nat i on. Two i dent i cal uni t s shal l be l ocat ed on t he mi ddl e wal l and t wo mi r r or ed uni t s l ocat ed on t he r i ver wal l . Each uni t shal l pr ovi de hydr aul i c power t o t he mi t er gat e cyl i nder and cul ver t val ve cyl i nder . They shal l be l ocat ed as shown on t he dr awi ngs. The power uni t shal l be compl et el y seal ed and capabl e of wat er submer gence t o a dept h 10 f eet wi t hout wat er i nf i l t r at i on. Each uni t shal l be equal t o t he uni t shown on t he dr awi ngs. Each uni t shal l be of t he gener al l ayout and not exceed t he si ze shown. Si ze t he oi l r eser voi r t o meet t he space l i mi t at i ons i ndi cat ed. Make t he r eser voi r of st ai nl ess st eel wi t h wel ded j oi nt s and conf or m t o t he r equi r ement s as shown. The r eser voi r s must conf or m t o t he r equi r ement s of I SO 4413. Each HPU shal l be a sel f - cont ai ned uni t capabl e of del i ver i ng up t o 75 gal l ons of hydr aul i c oi l per mi nut e at a pr essur e of 1000 pounds per squar e i nch. Oper at i ng demands on t he hydr aul i c power uni t wi l l var y f r om maxi mum del i ver y f or oper at i ng mi t er gat e and cul ver t val ve machi ner y at f ul l speed t o i nchi ng t he mi t er gat es i nt o posi t i on and t hen hol di ng l i ne pr essur e at t he pump compensat or set t i ng.

The hydr aul i c power uni t shal l not exceed a l engt h of 66 i nches, wi dt h of 54 i nches, and hei ght of 40 i nches. The st r uct ur e of t he uni t bot h i nt er nal l y and ext er nal l y shal l be adequat e f or t he uni t t o be f r eest andi ng and capabl e of bei ng l i f t ed or moved wi t hout st r uct ur al damage. Adequat el y r at ed l i f t i ng l ugs shal l be pr ovi ded t o f aci l i t at e pl aci ng t he uni t i n t he machi ner y r ecess. Al l component s i ncl udi ng pi pi ng, mot or s, pumps and mani f ol ds shal l be secur el y at t ached t o t he power uni t and i n a manner t o be f r ee of v i br at i on dur i ng oper at i on. The case dr ai n connect i on t o t he t ank and t he pr essur e connect i on bet ween t he pump and unl oadi ng mani f ol d shal l be made wi t h pr oper l y r at ed hose and f i t t i ngs. The pump mot or s shal l be mount ed t o t he power uni t on v i br at i on dampeni ng r ai l s. Shape and sl ope t he r eser voi r bot t om t o f aci l i t at e empt yi ng and cl eani ng. A f oot val ve or check suct i on l i nes must pr ovi de f l ooded i nl et s t o t he pump. Pr ovi de t he t op of t he r eser voi r wi t h a c l eanout openi ng of not l ess t han 200 squar e i nches cl ear ance wi t h a bol t ed, gasket ed cover , cent er ed over t he baf f l e. Pr ovi de each r eser voi r wi t h a dr ai n wi t h shut - of f val ve; l ow oi l l evel swi t ches; and ot her appur t enances as i ndi cat ed and as speci f i ed her ei n. Equi p t he r eser voi r wi t h a f l ui d l evel i ndi cat or . Pr ovi de a baf f l e bet ween t he i nt ake and r et ur n l i nes t o f aci l i t at e t he separ at i on of ai r and f or ei gn mat t er f r om t he hydr aul i c f l ui d. The connect i on bet ween t he t wo chamber s of t he r eser voi r must be hi gh enough f r om t he bot t om t o f or m a set t l i ng chamber .

A dr i p t r ay capabl e of cont ai ni ng t he f ul l r eser voi r vol ume shal l be pr ovi ded as shown on t he dr awi ngs.

The power uni t shal l be of a const ant pr essur e, var i abl e del i ver y t ype sui t abl e f or pumpi ng hydr aul i c oi l i nt o an open hydr aul i c syst em wher ei n a r el at i vel y const ant oper at i ng pr essur e i s mai nt ai ned. The const ant pr essur e, var i abl e del i ver y f unct i on shal l be accompl i shed by usi ng pr essur e compensat ed, var i abl e di spl acement pumps. The pumps shal l st ar t agai nst zer o pr essur e by i ni t i al l y vent i ng t he oi l back t o t ank. Af t er 10 seconds t he vent shal l c l ose and pump pr essur e shal l r i se t o t he pump compensat or set t i ng. Oi l t emper at ur e shal l be mai nt ai ned at a mi ni mum of 50 degr ees F. usi ng a t her most at i cal l y cont r ol l ed i mmer si on heat er l ocat ed i n a bul b wel l . The uni t shal l have bot h pr essur e and r et ur n l i ne f i l t er s and a c l osed br eat hi ng syst em f or t he r eser voi r . Fi ni sh t he wel ded j oi nt s of t he r eser voi r smoot h and f r ee f r om i r r egul ar i t i es. Do not gr i nd wel ds t o an ext ent t hat weakens t he r eser voi r . Unt i l f i nal i nst al l at i on of t he

SECTI ON 35 05 40. 14 10 Page 13 hydr aul i c equi pment , seal al l openi ngs wi t h pl ast i c c l osur es.

2. 2. 1 Motors

The el ect r i c mot or s f or t he pumps shal l be 60 hor sepower , 1800 r evol ut i ons per mi nut e, t ot al l y encl osed non- vent i l at ed or t ot al l y encl osed bl ower cool ed, pr emi um ef f i c i ency i nduct i on mot or s wi t h a 1. 15 ser vi ce f act or and shal l compl y wi t h Sect i on 40 95 00 PROCESS CONTROL. The mot or shal l be r at ed i mmer si bl e t o a mi ni mum dept h of 15 f eet f or up t o a week.

2. 2. 2 Mot or Coupl i ng

Mot or coupl i ng shal l be st eel and of t he f l exi bl e dr i ve t ype adequat el y r at ed wi t h a ser vi ce f act or of 1. 5 f or t he hor sepower and t or que bei ng t r ansmi t t ed. Posi t i ve means shal l be pr ovi ded f or secur i ng t he coupl i ng t o i t s r espect i ve shaf t s. I nst al l a scr een over t he coupl i ng access hol e t o pr ot ect t he shaf t f r om debr i s.

2. 2. 3 Pump

The hydr aul i c oi l pumps shal l be axi al pi st on t ype wi t h swashpl at e desi gn f or var i abl e di spl acement . The pump shal l be desi gned f or open ci r cui t oper at i on and shal l be sel f - pr i mi ng i n t he posi t i on shown. The pump shal l have an adj ust abl e const ant pr essur e cont r ol . The pump shal l be r at ed f or l ong ser vi ce l i f e and oper at e at a l ow noi se l evel . The pump shal l be SAE 2 or 4- bol t f ace mount ed. The por t connect i ons shal l be f l anged or SAE por t s. Each pump shal l be r at ed f or at l east a 3000 psi oper at i ng pr essur e, have a capaci t y of 75 gal l ons per mi nut e and 1000 psi wi t h oi l as her ei naf t er speci f i ed at appr oxi mat el y 50 degr ees F. Pump shal l be Par ker PV180, or equal . Vol ume st ops shal l be f act or y set t o l i mi t out put f l ow pr evi ousl y descr i bed r at es.

2. 2. 4 Pr essur e Rel i ef and Vent Val ve

A r el i ef and vent val ve shal l pr ovi de pr essur e r el i ef and vent i ng mechani cal l y. The val ve shal l have a mi ni mum pr essur e r at i ng of 3000 psi . The val ve must have t he capaci t y t o pass 75 gpm and must be f i el d adj ust abl e wi t hi n t he speci f i ed r el i ef pr essur e adj ust ment r ange Or i f i ces shal l be pr ovi ded as necessar y f or pr oper f unct i oni ng and smoot h oper at i on of t he val ve. The pr essur e r el i ef and vent val ve shal l be equal t o Par ker Ser i es 20SLC2A.

2. 2. 5 Check Val ve

A check val ve shal l be mount ed i n- l i ne t o cont r ol t he di r ect i on of f l ow.

The check val ve shal l have a mi ni mum pr essur e r at i ng of 3000 psi and shal l be of t he same manuf act ur er as t he pump. Or i f i ces shal l be pr ovi ded as necessar y f or pr oper f unct i oni ng and smoot h oper at i on of t he val ve. The pr essur e r el i ef and vent val ve shal l be equal t o Par ker Ser i es C5V.

2. 2. 6 Power Uni t Val ve Mani f ol d

A mani f ol d bl ock shal l be pr ovi ded f or each pump as shown i n t he dr awi ngs. The pr essur e f i l t er shal l be mount ed on t he mani f ol d and shal l have pr ovi s i ons f or i nst al l at i on of a by- pass r el i ef val ve, pr essur e gage and shut of f bal l val ve, t est por t , pr essur e swi t ch and t r ansducer her ei n descr i bed and as shown i n t he dr awi ngs. The mani f ol d shal l be made of st ai nl ess st eel and machi ned i n accor dance wi t h t he manuf act ur er s ' r ecommendat i ons t o pr ovi de f or i nst al l at i on of val ves, f l anges and

SECTI ON 35 05 40. 14 10 Page 14 accessor i es. Hydr aul i c i nt er connect i ons bet ween t he mani f ol d and pi pi ng shal l be made wi t h f l anges. The mani f ol d shal l be const r uct ed i n such a manner t hat i t may be r emoved f r om t he hydr aul i c power uni t by unbol t i ng f r om f l anges and mount i ng base. Const r uct i on of t he mani f ol d shal l be i n accor dance wi t h appl i cabl e r equi r ement s of t he par agr aph MANI FOLDS.

2. 2. 7 Pr essur e Gauge and Shut of f Val ve

A pr essur e gage wi t h a shut of f val ve shal l be i nst al l ed t o per mi t measur i ng pr essur e f or set t i ng t he r el i ef val ve and t he pump pr essur e compensat or and moni t or i ng syst em pr essur e. The gage shal l be l ocat ed so t hat i t i s r eadi l y v i s i bl e. The gage shal l be a 0 - 4000 psi Bour don t ube t ype wi t h f i xed or i f i ce snubber , st ai nl ess st eel body, and r i ght angl e shut of f val ve. The component s shal l have a mi ni mum pr essur e r at i ng of 3000 psi .

2. 2. 8 Hydr aul i c Power Uni t Pi pi ng

Al l pi pi ng shal l conf or m t o par agr aph POWER PI PI NG. Al l pi pe, f i t t i ngs and val ves on t he power uni t , not ot her wi se speci f i ed, shal l be desi gned f or a wor ki ng pr essur e of 1000 psi . Pi pi ng shal l be seaml ess st ai nl ess st eel pi pe or t ubi ng wi t h f or ged st eel socket wel ded f i t t i ngs. Bal l val ves shal l be pr ovi ded as shown and shal l have socket wel ded or f our bol t f l ange connect i ons. Pi pe, f i t t i ngs and bal l val ves shal l be as speci f i ed el sewher e her ei n. Fl anges on hydr aul i c power uni t whi ch connect t o t he pr essur e and t ank l i nes shal l be of t he same t ype and pr essur e r at i ng as t hose descr i bed her ei n under Power Pi pi ng. Fl anges connect i ng t o t he pump por t shal l be of t he socket wel ded SAE 4- bol t t ype t o mat ch t he pump bol t i ng pat t er n. Fl anges connect i ng pi pi ng t o t he mani f ol d shal l be a 3000 psi f l at socket wel ded t ype.

2. 2. 9 Oi l St or age Tank

The oi l st or age t ank shal l have a mi ni mum capaci t y of 150 gal l ons of oi l .

The t ank shal l be of wel ded, Type 304 or 304L st ai nl ess st eel const r uct i on wi t h ends, s i des and bot t om havi ng a mi ni mum t hi ckness of 3/ 8- i nch. The t ank shal l be s l oped t o dr ai n and pr ovi ded wi t h an i nt er nal baf f l e as shown. Al l ent r ances of pi pi ng i nt o t he t ank shal l be made t hr ough st ai nl ess st eel socket wel ded coupl i ngs. The t her most at and heat er bul b wel l s shal l be st ai nl ess st eel . Ext er nal suppor t member s f or t he t ank, pumps, mot or s and val ve mani f ol ds shal l be made f r om st ai nl ess st eel and shal l pr ovi de r i gi d suppor t f or t he t ank and al l component s. The t ank shal l be t est ed f or l eaks at a pr essur e of 205 pounds per squar e i nch bef or e f i nal assembl y.

2. 2. 10 Top Cl eanout and Cover

Each power uni t shal l be pr ovi ded wi t h one cl eanout openi ng wi t h t op cover as shown t o pr ovi de access f or c l eani ng and r epai r s i nsi de t ank. The cover shal l be of adequat e t hi ckness and cor r ect l y gasket ed t o pr event any l eakage of oi l . Cover shoul d be cent er ed over t he baf f l e t o al l ow access t o ei t her s i de of t he r eser voi r .

2. 2. 11 Oi l Level Si ght Gauge

An oi l l evel gage shal l be pr ovi ded on each uni t and shal l be posi t i oned t o gi ve a v i sual i ndi cat i on of t he oi l l evel i n t he t ank i ncl udi ng t he " l ow l evel " , " add oi l l evel " , " nor mal mi ni mum l evel " , and " maxi mum l evel " mar ks. Af t er t he syst em i s oper at i onal and al l t est s compl et e, t he l evel s

SECTI ON 35 05 40. 14 10 Page 15 shal l be per manent l y mar ked on t he t ank i n a manner appr oved by t he Cont r act i ng Of f i cer s or hi s aut hor i zed r epr esent at i ve.

2. 2. 12 Tank Dr ai n

A t ank dr ai n wi t h val ve and pl ug shal l be pr ovi ded t o dr ai n t he f ul l vol ume of t he r eser voi r .

2. 2. 13 Magnet i c Separ at or s

Pr ovi de t he manuf act ur er ' s st andar d magnet i c separ at or i n t he r eser voi r .

The magnet i c separ at or consi st s of a hi gh- st r engt h per manent magnet ar r anged f or r i gi d mount i ng wi t h t he pol es of t he magnet exposed t o t he f l ui d i n t he r eser voi r . The magnet must be i ncor por at ed i n t he bot t om dr ai n pl ug.

2. 2. 14 Fl ow Swi t ch

The pr essur e pi pi ng shal l have an i n- l i ne f l ow swi t ch l ocat ed near t he pump out l et . The f l ow swi t ch shal l be a t r i mmabl e vane t ype t hat i s set t o act uat e at 10 gpm. The swi t ches shal l be compat i bl e wi t h t he hydr aul i c oi l . The f l ow swi t ch shal l be weat her pr oof , meet i ng I P66 or bet t er . Seal t er mi nal s, el ect r i cal connect or s, cabl es, and j unct i ons wi t h di el ect r i c gr ease as necessar y t o achi eve a r at i ng equi val ent t o I P67. The t her most at shal l be r at ed f or 24 VDC. I nst al l at i on shal l be i n accor dance wi t h appl i cabl e r equi r ement s of Sect i on 40 95 00 PROCESS CONTROL.

2. 2. 15 Reser voi r Heat er wi t h I nt egr al Ther most at and Swi t ch

Pr ovi de a 2, 000 wat t i mmer si on heat er sui t abl e f or use i n a bul b wel l as i ndi cat ed t o keep t he oi l i n t he t ank at a mi ni mum t emper at ur e of 50 degr ees F. wi t h an ambi ent t emper at ur e of 0 degr ees F. Wat t densi t y f or t he heat er wel l shal l not exceed 11 wat t s per squar e i nch at t he desi gn vol t age. The heat er shal l be a 480 vol t , 3 phase heat er . The heat er shal l have a bui l t - i n t her most at t o sense t he oi l t emper at ur e i n t he t ank and cl ose i t s cont act s when t he t emper at ur e dr ops bel ow 50 degr ees F and open i t s cont act s when t he oi l t emper at ur e r eaches 80 degr ees F. The t emper at ur e adj ust ment r ange shal l be 20 degr ees t o 200 degr ees F wi t h 2 degr ee di f f er ent i al swi t ch. The t er mi nal encl osur e shal l be weat her - pr oof and r at ed I P66 or bet t er . Seal t er mi nal s, el ect r i cal connect or s, cabl es, and j unct i ons wi t h di el ect r i c gr ease as necessar y t o achi eve a r at i ng equi val ent t o I P67. I nst al l at i on shal l be i n accor dance wi t h appl i cabl e r equi r ement s of Sect i on 40 95 00 PROCESS CONTROL.

2. 2. 16 Hi gh Temper at ur e Swi t ch

Pr ovi de a t her most at t o sense t he oi l t emper at ur e i n t he t ank and cl ose i t s cont act s when t he t emper at ur e exceeds 150 degr ees F as i ndi cat ed.

Hi gh t emper at ur e swi t ch can be i nt egr at ed i n t he l evel swi t ch. The t emper at ur e adj ust ment r ange shal l be 10 degr ees t o 200 degr ees F wi t h 2 degr ee di f f er ent i al swi t ch. The swi t ch shal l be weat her pr oof , meet i ng I P66 r at i ng or bet t er . Seal t er mi nal s, el ect r i cal connect or s, cabl es, and j unct i ons as necessar y t o achi eve a r at i ng equi val ent t o I P67. The t her most at shal l be r at ed f or 24 VDC. I nst al l at i on shal l be i n accor dance wi t h appl i cabl e r equi r ement s of Sect i on 40 95 00 PROCESS CONTROL.

SECTI ON 35 05 40. 14 10 Page 16

2. 2. 17 Level Swi t ches

2. 2. 17. 1 Reser voi r Tank Level

Each power uni t shal l be pr ovi ded wi t h a l evel sensor wi t h t wo ( 2) l evel swi t ches i n t he st or age t ank. The swi t ches shal l be compat i bl e wi t h t he hydr aul i c oi l . Swi t ches shal l be set t o c l ose when oi l l evel dr ops bel ow t he r equi r ed l evel f or pr oper syst em oper at i on and shal l be r at ed f or 24 VDC. The swi t ch shal l be weat her pr oof , meet i ng I P67 r at i ng or bet t er .

I nst al l at i on shal l be i n accor dance wi t h t he appl i cabl e r equi r ement s of Sect i on 40 95 00 PROCESS CONTROL.

2. 2. 17. 2 Dr i p Pan

Each power uni t shal l be pr ovi ded wi t h one ( 1) f l oat swi t ch i n t he mai n dr i p pan. The swi t ch shal l have a br ass body and a Buna- N f l oat . The swi t ch shal l be compat i bl e wi t h t he hydr aul i c oi l . The swi t ch shal l be i nst al l ed on a cast j unct i on box as shown on t he dr awi ngs. The SPST r eed swi t ch shal l be r at ed f or 0. 7 amper es at 120 vol t s AC. The swi t ch shal l meet I P67 r at i ng or bet t er . The swi t ch shal l be i nst al l ed as l ow as possi bl e and set t o c l ose when oi l accumul at es i n t he dr i p pan. The swi t ch shal l be equal t o I nnovat i ve Component s LS- 12- 110. I nst al l at i on shal l be i n accor dance wi t h t he appl i cabl e r equi r ement s of Sect i on 40 95 00

PROCESS CONTROL.

2. 2. 18 Reser voi r I sol at or

Each HPU shal l be pr ovi ded wi t h one r eser voi r i sol at or uni t t o el i mi nat e t he i nt r oduct i on of out s i de ai r dur i ng nor mal oper at i on of t he syst em.

Each i sol at or shal l have a capaci t y no l ess t han 45 gal l ons. The r eser voi r i sol at or shal l have a bl adder compat i bl e wi t h t he syst em hydr aul i c f l ui d. The shel l shal l be f r ee st andi ng and of r ugged st eel const r uct i on. The br eat her const r uct i on and mount i ng shal l be i n a manner t o f aci l i t at e bl adder r epl acement . The por t connect i on shal l be an SAE #24 . The uni t s shal l be mount ed hor i zont al l y on a common st eel base i n t he t r ench/ gal l er y near t he machi ner y r ecess. The common st eel base shal l be secur el y at t ached t o t he f l oor or wal l . Anchor bol t s f or t he st eel base shal l be suf f i c i ent t o r esi st buoyancy of t he r eser voi r i sol at or when i nst al l ed and submer ged.

2. 2. 19 I sol at or Pi pi ng

The connect i on bet ween t he hydr aul i c power uni t and t he r eser voi r i sol at or shal l be by hose sui t abl e f or vacuum ser vi ce. Sui t abl e connect i ons shal l be pr ovi ded t o f aci l i t at e r epai r or r epl acement of t he f l exi bl e r eser voi r bl adder . A l ockabl e i sol at i on val ve shal l be pr ovi ded t o pr event acci dent al c l osi ng of t he r eser voi r br eat her connect i on.

2. 2. 20 Pr essur e Rel i ef and Emer gency Vent i ng

A pr essur e r el i ef syst em consi st i ng of i nl i ne check val ves and br eat her s shal l be pr ovi ded i n t he i sol at or pi pi ng. Thi s wi l l pr event col l apse or " oi l canni ng" of t he t ank. The check val ve i n l i ne wi t h t he i sol at or shal l be r emovabl e t o per mi t vent i ng t he r eser voi r dur i ng set up or ext r a or di nar y oper at i on. The ai r i n t he t ank wi l l be di r ect ed t o t he i sol at or dur i ng nor mal oper at i ons. The br eat her s shal l be of t he t hr eaded t ype wi t h st eel shel l and nyl on st r ai ner and guar d and r at ed f or 75 cubi c f eet per mi nut e. The i nl i ne f r ee f l ow check val ves shal l be t he t hr eaded t ype wi t h a 2 psi cr acki ng pr essur e.

SECTI ON 35 05 40. 14 10 Page 17

2. 2. 21 Pr essur e Swi t ches

The pr essur e pi pi ng shal l have a dual set poi nt pr essur e swi t ch l ocat ed near t he pump out l et . The pr essur e swi t ch set poi nt s shal l be i ndependent l y adj ust abl e wi t h a f i xed deadband. The encl osur e and swi t ch shal l be weat her pr oof , meet i ng I P66 r at i ng or bet t er . Seal t er mi nal s, el ect r i cal connect or s, cabl es, and j unct i ons wi t h di el ect r i c gr ease as necessar y t o achi eve a r at i ng equi val ent t o I P67. The t her most at shal l be r at ed f or 24 VDC. I nst al l at i on shal l be i n accor dance wi t h t he appl i cabl e r equi r ement s of Sect i on 40 95 00 PROCESS CONTROL.

2. 2. 22 Pr essur e Gauges and Snubber s

Conf or m t o ASME B40. 100 4- 1/ 2 i nch di al , and a st ai nl ess st eel Bour don t ube. The scal e r ange of t he gauge must be appr oxi mat el y 150 per cent of t he maxi mum pr essur e of t he l i ne i n whi ch i nst al l ed. Pr ovi de saf et y t ype gauges wi t h sol i d f r ont s and bl owout backs. Mount gauge as i ndi cat ed.

Bot t om t ap gauges and gauge l i nes i n hor i zont al pr essur e l i nes. Pr ovi de pr essur e snubber s f or al l pr essur e gauges and pr essur e swi t ches t o pr ot ect agai nst shock and pr ovi de mor e st abl e i nst r ument oper at i on. Snubber s must be of st ai nl ess st eel const r uct i on.

2. 2. 23 Pr essur e Fi l t er

Each hydr aul i c power uni t shal l be pr ovi ded wi t h a pr essur e f i l t er mount ed as shown on t he dr awi ngs.