41_24_26_-_Amendment_4.pdf

Braddock Locks Interlock Control System Replacement

SECTION TABLE OF CONTENTS

DIVISION 41 - MATERIAL PROCESSING AND HANDLING EQUIPMENT

SECTION 41 24 26

HYDRAULIC FLUID POWER SYSTEMS

PART 1 GENERAL

1.1 REFERENCES

1.2 DEFINITIONS

1.3 SUBMITTALS

1.4 QUALITY ASSURANCE

1.4.1 Welding

1.4.2 Stringent Requirements

1.5 DELIVERY, STORAGE, AND HANDLING

1.6 EXTRA MATERIALS

PART 2 PRODUCTS

2.1 MATERIALS AND EQUIPMENT

2.1.1 Standard Products

2.1.2 Nameplates

2.1.3 Prevention of Corrosion

2.2 VALVES

2.2.1 Directional Control Valves

2.2.2 Isolation Valves

2.2.3 Ball Valves

2.2.4 Valve Mounting

2.3 LINES AND FITTINGS

2.3.1 Pipe

2.3.2 Pipe Fittings and Flanges

2.3.3 Manifolds

2.4 HYDRAULIC FLUID

2.5 PACKING, GASKETS, AND SEALS

2.5.1 Static Seals

2.6 ACCESSORIES

2.6.1 Bolts, Nuts and Cap Screws

2.6.2 Locknuts

2.6.3 Methods of Securing Fasteners

2.6.4 Pipe Hangers and Supports

2.6.5 Shims

2.6.6 Equipment Bases

2.7 CONTROL COMPONENTS

2.7.1 Control Devices and Wiring

2.7.2 Valve Operating Lever Limit Switches

2.7.3 Proximity Limit Switch

2.7.4 Manual Switches

2.7.5 Relays

2.7.6 Indicating Lights

2.8 TEMPORARY CORROSION PROTECTION

2.9 PAINTING

2.9.1 Cleaning And Preparation Of Surfaces To Be Painted

SECTION 41 24 26 Page 1 Certified Final Documents - RTA W911WN19B8006 - Amendment 4

2.9.1.1 General Requirements

2.9.1.2 Ferrous Surfaces Exposed to Atmosphere

2.9.2 Paint Application

2.9.2.1 General

2.9.2.2 Mixing and Thinning

2.9.2.3 Atmospheric and Surface Conditions

2.9.2.4 Time Between Surface Preparation and Painting

2.9.2.5 Method of Paint Application

2.9.2.6 Coverage and Film Thickness

2.9.2.6.1 Measurement on Ferrous Metal

2.9.2.7 Progress of Painting Work

2.9.2.8 Protection of Painted Surfaces

2.9.3 Paint Systems Application

2.9.3.1 Surface Preparation

2.9.3.2 System No. 23-D

2.9.4 Painting Schedule

2.9.4.1 Finish Colors

PART 3 EXECUTION

3.1 EXAMINATION

3.2 INSTALLATION

3.2.1 Installation Drawing Submittal

3.2.2 Components and Subassemblies

3.2.3 Rigid Conductors

3.2.4 Flexible Conductors

3.2.5 Welded Installation

3.2.6 Special Considerations

3.3 MANUFACTURERS' FIELD SERVICES

3.3.1 Hydraulic Technician

3.3.2 Field Instructions Preparation

3.4 FIELD TESTS AND CLEANING OF HYDRAULIC LINES

3.4.1 Field Training

3.4.1.1 Operation Manual

3.4.1.2 Maintenance Manual

3.4.2 Hydraulic System Final Acceptance Tests

3.4.2.1 Preparation

3.4.2.2 Conducting Final Acceptance Tests

3.4.2.2.1 Initial Start-Up

3.4.2.2.2 Combined System Tests

3.4.2.2.3 Test Logs

3.5 PAINTING AND COLOR CODING

3.5.1 Painting

3.5.2 Field Touch-Up

-- End of Section Table of Contents --

SECTION 41 24 26 Page 2

SECTION 41 24 26

HYDRAULIC FLUID POWER SYSTEMS

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

ASME INTERNATIONAL (ASME)

ASME B1.1 (2003; R 2018) Unified Inch Screw Threads (UN and UNR Thread Form)

ASME B16.11 (2016) Forged Fittings, Socket-Welding and Threaded

ASME B16.5 (2017) Pipe Flanges and Flanged Fittings NPS 1/2 Through NPS 24 Metric/Inch Standard

ASME B18.2.1 (2012; Errata 2013) Square and Hex Bolts and Screws (Inch Series)

ASME B18.2.2 (2015) Nuts for General Applications:

Machine Screw Nuts, Hex, Square, Hex Flange, and Coupling Nuts (Inch Series)

ASME B18.6.2 (1998; R 2010) Slotted Head Cap Screws, Square Head Set Screws, and Slotted Headless Set Screws: Inch Series

ASME B31.1 (2016; Errata 2016) Power Piping

ASSOCIATION FOR IRON AND STEEL TECHNOLOGY (AIST)

AIST PB-229 (2008) Stainless Steels: A Steel Products Manual

ASTM INTERNATIONAL (ASTM)

ASTM A106/A106M (2018) Standard Specification for Seamless Carbon Steel Pipe for High-Temperature Service

ASTM A182/A182M (2018) Standard Specification for Forged or Rolled Alloy and Stainless Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service

ASTM A234/A234M (2018) Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature

SECTION 41 24 26 Page 3

Service

ASTM A36/A36M (2014) Standard Specification for Carbon Structural Steel

ASTM A574 (2017) Standard Specification for Alloy Steel Socket-Head Cap Screws

ASTM B117 (2016) Standard Practice for Operating Salt Spray (Fog) Apparatus

ASTM D3951 (2015) Commercial Packaging

ASTM D7091 (2013) Standard Practice for Nondestructive Measurement of Dry Film Thickness of Nonmagnetic Coatings Applied to Ferrous Metals and Nonmagnetic, Nondestructive Coatings Applied to Non-Ferrous Metals

INDUSTRIAL FASTENERS INSTITUTE (IFI)

IFI 100/107 (2002) Prevailing Torque-Type Steel Hex and Hex Flange Nuts Regular and Light Hex Series

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 10763 (1994) Hydraulic Fluid Power - Plain-end, Seamless and Welded Precision Steel Tubes

- Dimensions and Nominal Working Pressures

ISO 11727 (1999) Pneumatic Fluid Power - Identification of Ports and Control Mechanisms of Control Valves and Other Components

ISO 5598 (2008) Fluid Power Systems and Components

- Vocabulary

ISO 9461 (1992) Hydraulic Fluid Power - Identification of Valve Ports, Subplates, Control Devices and Solenoids

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS

INDUSTRY (MSS)

MSS SP-58 (2009) Pipe Hangers and Supports - Materials, Design and Manufacture, Selection, Application, and Installation

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS 1 (2000; R 2015) Standard for Industrial Control and Systems: General Requirements

NEMA ICS 2 (2000; R 2005; Errata 2008) Industrial Control and Systems Controllers, Contactors, and Overload Relays Rated 600 V

SECTION 41 24 26 Page 4

NEMA ICS 6 (1993; R 2016) Industrial Control and Systems: Enclosures

NATIONAL FLUID POWER ASSOCIATION (NFLPA)

NFLPA T2.13.1 (2007; 5th Ed) Recommended Practice – Hydraulic Fluid Power – Use Of Fire Resistant Fluids In Industrial Systems

NFLPA T3.28.9 (1989; R 2009; 2nd Ed) Fluid Power Systems and Products - Moving Parts Fluid Controls

- Method of Diagramming

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC Paint 41 (2008) Moisture-Cured Polyurethane Primer or Intermediate Coat, Micaceous Iron Oxide Reinforced, Performance-Based

SSPC SP 1 (2015) Solvent Cleaning

SSPC SP 3 (1982; E 2004) Power Tool Cleaning

SSPC SP 6/NACE No.3 (2007) Commercial Blast Cleaning

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

SAE J518-1 (2013) Hydraulic Flanged Tube, Pipe, and Hose Connections, 4-Screw Flange Connection Part 1: 3.5 MPa to 35 MPa (Code 61)

UNDERWRITERS LABORATORIES (UL)

UL Electrical Appliance (2012) Electrical Appliance and Utilization Equipment Directory

1.2 DEFINITIONS

The definitions of terms having a unique meaning in fluid power technology shall be those given in ISO 5598 .

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Detail Drawings; G , DO

Installation; G , DO

SD-03 Product Data

SECTION 41 24 26 Page 5

Spare Parts; G , DO

Field Instructions; G , DO

Valves; G, DO

Fittings; G, DO

Anchor Bolts; G, DO

SD-04 Samples

Hydraulic Fluid

SD-06 Test Reports

Field Tests and Cleaning of Hydraulic Lines

Inspection And Operation Records

SD-10 Operation and Maintenance Data

Operation and Maintenance Manuals; G , DO

Field Tests and Cleaning of Hydraulic Lines; G , DO

1.4 QUALITY ASSURANCE

1.4.1 Welding

1.4.2 Stringent Requirements

Welding and nondestructive testing procedures for piping are specified in Section 40 05 13.96 WELDING PROCESS PIPING.

1.5 DELIVERY, STORAGE, AND HANDLING

Protect equipment delivered and placed in storage from the weather, humidity and temperature variation, dirt and dust, or other contaminants.

1.6 EXTRA MATERIALS

Submit spare parts data for each different item of material and equipment specified, after approval of detail drawings and not later than 2 months prior to the date of beneficial occupancy. Include in the data a complete list of parts and supplies, including lubricants and fluids, current unit prices, sources of supply, and a list of the parts recommended by the manufacturer to be replaced after 3 years of service.

PART 2 PRODUCTS

2.1 MATERIALS AND EQUIPMENT

2.1.1 Standard Products

Provide materials and equipment which are the standard products of a manufacturer regularly engaged in the manufacture of the products and that essentially duplicate items that have been in satisfactory use for at least 2 years prior to bid opening. Items of the same classification

SECTION 41 24 26 Page 6 shall be identical, including equipment, assemblies, parts, and components. Equipment shall be supported by a service organization that is, in the opinion of the Contracting Officer, reasonably convenient to the site.

2.1.2 Nameplates

The manufacturer's name, address, and catalog number shall be permanently displayed on a plate securely attached to each major item of equipment.

Electrical equipment listed in UL Electrical Appliance shall have UL label or registration plate securely attached to the item of equipment.

2.1.3 Prevention of Corrosion

Provide fasteners and nameplates of corrosion-resistant materials.

Surfaces of products, such as pumps, cylinders, fluid motors, and similar components, of ferrous metal, where not otherwise specified, shall be given a corrosion-protective coating at the factory. Manufacturers' standard coatings are acceptable, provided that coatings for interior use can withstand continuous exposure to salt spray for 120 hours and coatings for exterior use for 504 hours. The fog test shall conform to ASTM B117.

Immediately after completion of the test, coating shall show no signs of wrinkling, cracking, or loss of adherence, and the specimen shall show no signs of corrosion creepage beyond l/8 inch on either side of the scratch mark made as specified. If coated samples have successfully withstood the salt spray test within the preceding 2 years, certificates will be acceptable in lieu of testing.

2.2 VALVES

Valves used in the hydraulic system lines shall be specially designed and rated for use in hydraulic systems. Valves shall have published pressure ratings not less than the maximum pressure ratings indicated for the circuit in which installed. Identification of ports, pilot and solenoid actuators and solenoid leads shall be as indicated by symbols conforming to ISO 9461 and ISO 11727 .

2.2.1 Directional Control Valves

Directional control valves that are manifold mounted, four-way, three-position spool type valves, Model No. DG5S4L-102C as manufactured by Eaton Hydraulics or equal, shall be provided as indicated in the contract drawings. The valves shall be solenoid operated, spring centered, closed center, internally piloted and drained, internally piloted and drained, with provisions for manual operation. The minimum flow and pressure rating for the valve shall be 40 GPM and 1000 psi, respectively. The valve shall be connected to a 120VAC 60HZ service.

2.2.2 Isolation Valves

Isolation valves that are manifold mounted, two-way, two-position normally closed spool type valves, Model No. DG5S4L-102F as manufactured by Eaton Hydraulics or equal, shall be provided as indicated in the contract drawings. The valves shall be solenoid operated, shift to center from spring offset, closed center, internally piloted and drained, internally piloted and drained. The minimum flow rating shall be 40 GPM, and the minimum pressure rating shall be 1000 psi. The valve shall be connected to a 120VAC 60Hz electrical service.

SECTION 41 24 26 Page 7

2.2.3 Ball Valves

Multiple piece body in-line ball valves, 1.5 to 2 inch, shall have two or three piece bodies constructed of carbon steel and with socket weld connections. Valves shall be rated for 1000 psig service, shall conform to ASME B16.34 Class 600, and shall be equipped with hand lever operators with a lockable handle.

As indicated in the contract drawings, two ball valves per manifold shall be provided with an indicating limit switch. The switch shall provide a signal as shown on the contract drawings. The switch shall be connected to a 120 VAC 60 Hz electrical service.

2.2.4 Valve Mounting

Directional and Isolation Valve mounting provisions shall be manifold as indicated. Ball valves shall be in-line. The Contractor is responsible for determining final location of the manifold within the recess prior to anchoring the manifold to the recess wall with anchor bolts suitable for the application, per the manifold manufacturer's recommendation.

2.3 LINES AND FITTINGS

Piping and tubing connections shall be designed and installed to permit quick removal and reassembly with hand tools. The hydraulic system is rated at 800 psig service at 150 degrees F with a maximum flow of 80 GPM.

2.3.1 Pipe

Unless otherwise indicated, hydraulic pipe shall be seamless steel pipe conforming to ASTM A106/A106M , Grade B. Piping weight class shall be extra strong. Pipe shall conform to the cleanliness requirements of

ISO 10763 .

2.3.2 Pipe Fittings and Flanges

Pipe fittings shall be steel. Welded fittings shall conform to ASTM A234/A234M , Grade WPB. Flanges, bolts, and gaskets shall be in accordance with ASME B31.1 or SAE J518-1 Code 61. Flange bolts shall be steel and shall have steel self-locking nuts. The seals shall be compatible with the hydraulic fluid used in the system. Threaded fittings shall not be used. Flanges shall conform to ASTM A182/A182M , grade suitable for pipe to which attached. Facing on flanges shall be in accordance with ASME B16.5 . Unions shall be Class 3000 socket fittings made of forged steel conforming to ASME B16.11 .

2.3.3 Manifolds

Provide manifolds where indicated. Each manifold must be cast or machined from solid plate. Machine smooth ports and passages, free of burrs and sharp edges. Machine surfaces to which valves and other components will be mounted smooth and flat to the specifications of the applicable valve or component manufacturer. Machine counterbores to hold O-ring port seals to dimensions recommended by the O-ring manufacturer. The manifolds shall be designed for an internal operating pressure of not less than 1,500 psi.

Components shall be located on the manifold in positions where they may be readily replaced or adjusted after installation. All components shall be mounted to the manifold in accordance with the manufacturer's instructions.

SECTION 41 24 26 Page 8

2.4 HYDRAULIC FLUID

Supply a sufficient amount of hydraulic fluid, of the type specified and as recommended by the fluid manufacturer, to completely fill the new piping system initially plus at least 10 percent additional reserve fluid. Also provide extra fluid to make up all losses resulting from venting operations, from leakage and from all other causes before final acceptance. Check the fluid level and bring to the proper operating level immediately after satisfactory completion of final acceptance tests.

Deliver the hydraulic fluid to the site in unopened containers with factory seals intact. Clearly label containers in accordance with ASTM D3951. Hydraulic fluids must be certified by the manufacturer as fire-resistant in conformance with NFLPA T2.13.1 . Fluid shall be synthetic type. Fresh hydraulic fluid shall be filtered to 10 micron level.

2.5 PACKING, GASKETS, AND SEALS

Hydraulic components shall be equipped with seals, packings, gaskets, and O-rings selected and recommended by the respective manufacturers for maximum compatibility with the particular hydraulic fluid specified for use in the system.

2.5.1 Static Seals

Static-type seals shall be arranged to seal with pressure and shall be provided with backup rings or other approved confining devices to prevent material extrusion during expansion and contraction resulting from pressure and temperature changes. Static-type seals shall be continuous rings.

2.6 ACCESSORIES

Accessories shall conform to the following:

2.6.1 Bolts, Nuts and Cap Screws

ASME B18.2.1 , ASME B18.2.2 , ASME B18.6.2 or ASTM A574, as applicable. All bolts, cap screws, and nuts not otherwise indicated or specified shall be medium carbon steel and shall be cadmium plated. Threads shall conform to

ASME B1.1 .

2.6.2 Locknuts

IFI 100/107 for hexagon locknuts, prevailing torque type, or a type standard with the manufacturer provided they meet or exceed the requirements of the IFI specifications.

2.6.3 Methods of Securing Fasteners

All fasteners not secured by mechanical devices, such as lock washers, cotter pins, safety wire, or locknuts, shall have the threaded portion of the fastener coated with sealing/locking compound, Grade E or Grade B, as applicable, before installation. Fasteners shall be cleaned of all rust-inhibiting compounds and lubricants before applying the sealing/locking compound.

SECTION 41 24 26 Page 9

2.6.4 Pipe Hangers and Supports

MSS SP-58 . Pipe shall be supported at all changes in direction, and at all valve locations. Pipes shall be supported at a spacing not to exceed 7 feet for straight runs.

2.6.5 Shims

Shims shall be provided in graduated thicknesses which shall permit adjustment in increments of 0.005 inches from 0 to 1/4 inch. Shims for use between machinery components, subassemblies, or machinery bases and mounting brackets and unfinished surfaces of structural members shall provide adjustment in increments of 1/32 inch from 1/4 inch to 150 percent of the shim allowance indicated. Tapered shims shall be provided as required to accurately align machinery components and bases which are mounted directly to unfinished structural steel surfaces. Field measurements shall be taken to determine the exact amount of taper required to obtain proper alignment. Material for all shims shall be AIST PB-229 , Types 304 or 316 unless otherwise indicated.

2.6.6 Equipment Bases

Nonintegral equipment bases including brackets and mounts shall be all-welded construction and shall be fabricated of ASTM A36/A36M steel.

2.7 CONTROL COMPONENTS

2.7.1 Control Devices and Wiring

Manual or automatic control protective or signal devices required for the specified operation and all control wiring for these controls and devices shall be provided whether indicated or not. Electrical control devices shall have minimum current and voltage ratings in accordance with the requirements of NEMA ICS 2 contact rating designation A 300, as applicable, unless larger ratings are indicated or required. Control devices shall be provided with the number and arrangement of contacts required to perform the specified control functions. Devices shall be provided with or installed in NEMA Type 4 for exterior application enclosures as indicated. Components shall be electronically and electrohydraulically controlled as indicated.

2.7.2 Valve Operating Lever Limit Switches

Limit switches shall be neutral position rotating type having activating mechanisms of the fork type required to detect the neutral position of the valve control linkages. The switches shall be similar or equal to Eaton E50NN19 series. The switches shall operate the contacts after 5 degrees of travel from the neutral position, have a total travel of 90 degrees, and be rated to temperatures of between -30 and 130 degrees Fahrenheit. The forks shall be suitably large to be positioned on either side of the valve control linkages as indicated on the drawings. The switches shall be in a case conforming to NEMA ICS 6 Type 6P. Activating mechanisms and switch mountings shall be arranged so that over travel of the monitored member will not damage the activator and switch.

2.7.3 Proximity Limit Switch

The proximity switches shall be unshielded 120VAC, switch rating, single or double double pole, double throw, 1 or 2 forms C's. Switch rating: 1250

SECTION 41 24 26 Page 10 watts at 120, 240, 600 VAC. Maximum cycle rate of 10 cycles per minute resistive load at 10 amps. Sensing distance of approximate 5/16", side sensing. NEMA 6P designed for submersion, with stainless steel barrel and housing. The cable entrance and wire strands shall be epoxy sealed to protect against the entrance of water into the switch. The switch shall be factory pre-wired using SOOW-A rated cable. The Contractor shall determine the cable length required. The Contractor shall be responsible for adjusting the limit switches for proper operation at the normal machinery end-of-travel position. Limit switches shall be similar or equal to TopWorx Go Switch, Model 11 or Model 81 limit switches.

2.7.4 Manual Switches

Manually-operated switches, including pushbutton switches, selector switches and key-operated switches, shall be heavy-duty oil-tight type conforming to the requirements of NEMA ICS 1 . Switches shall be momentary contact type with standard operators except where maintained contacts or special operators, such as mushroom head, illuminated button, and latching button are indicated.

2.7.5 Relays

Relays used in control circuits shall be industrial magnetic control relays conforming to NEMA ICS 2 contact rating designation A 300, except where other ratings are indicated. Relays shall be applied in control circuits in such a manner that proper control functions shall be obtained regardless of whether the contacts are overlapping or nonoverlapping.

2.7.6 Indicating Lights

Indicating lights shall be the oil-tight type with jewel color as indicated. Light unit shall be the integral transformer type with 6-8 volt lamp and shall be fitted with a glass color cap.

2.8 TEMPORARY CORROSION PROTECTION

Unpainted metal surfaces shall be protected from corrosion during shipment, storage at the site, and during construction operations so that the surfaces are free of corrosion until application of final field finish. The temporary coating shall be completely removed and the surfaces properly prepared for final finishing as specified in paragraph PAINTING. Products, including pumps, reservoirs, cylinders, and similar assemblies, shall not be provided unpainted or with temporary coating, but shall be factory finished as specified.

2.9 PAINTING

Shop prime and coat all exposed exterior surfaces of assemblies and equipment except stainless steel, synthetic rubber, and plastic, as specified unless the equipment is given a standard factory finish as allowed by other paragraphs of this specification. Insofar as is practicable, apply the complete coating system to individual components and items before assembly to ensure complete coverage and maximum protection against corrosion. Paint shop assembled equipment prior to any storage or shipment. Do not paint aluminum, stainless steel or non-ferrous surfaces, except as approved by the Contracting Officer.

Paint standard manufactured equipment, such as motors, pumps, hydraulic cylinders, valves, in accordance with the manufacturer's standard practice for high humidity service, subject to approval by the Contracting

SECTION 41 24 26 Page 11

Officer. Repair chips, scratches, and other damage to shop-applied painted surfaces in the field.

2.9.1 Cleaning And Preparation Of Surfaces To Be Painted

2.9.1.1 General Requirements

Surfaces to be painted shall be cleaned before applying paint or surface treatments. Deposits of grease or oil shall be removed in accordance with SSPC SP 1 , prior to mechanical cleaning. Solvent cleaning shall be accomplished with mineral spirits or other low toxicity solvents having a flash point above 100 degrees F. Clean cloths and clean fluids shall be used to avoid leaving a thin film of greasy residue on the surfaces being cleaned. Items not to be prepared or coated shall be protected from damage by the surface preparation methods. Machinery shall be protected against entry of blast abrasive and dust into working parts. Cleaning and painting shall be so programmed that dust or other contaminants from the cleaning process do not fall on wet, newly painted surfaces, and surfaces not intended to be painted shall be suitably protected from the effects of leaning and painting operations. Welding of, or in the vicinity of, previously painted surfaces shall be conducted in a manner to prevent weld spatter from striking the paint and to otherwise reduce coating damage to a minimum; paint damaged by welding operations shall be restored to original condition. Surfaces to be painted that will be inaccessible after construction, erection, or installation operations are completed shall be painted before they become inaccessible.

Appropriate measures shall be taken to prevent abrasives, debris, paint, thinners or other materials from entering the river during field painting. Machinery and structures adjacent to surfaces to be painted shall be adequately protected to prevent damage resulting from the cleaning and painting operations. Damage to adjacent items shall be repaired to the satisfaction of the Contracting Officer at no additional cost to the Government. Paint on surfaces not intended to be painted shall be completely removed.

2.9.1.2 Ferrous Surfaces Exposed to Atmosphere

Ferrous surfaces shall be cleaned and commercial blast cleaned in accordance with the requirements of SSPC SP 6/NACE No.3 for shop painting or SSPC SP 3 for field touchup. Welds and adjoining surfaces within a few inches thereof shall be cleaned of weld flux, spatter, and other harmful deposits. Welds and adjacent surfaces cleaned thoroughly by blasting alone will be considered adequately prepared provided that weld spatter not dislodged by the blast stream shall be removed with impact or grinding tools. All surfaces shall be primed as soon as practicable after cleaning but prior to contamination or deterioration of the prepared surfaces. To the greatest degree possible, steel surfaces shall be cleaned (and primed) prior to lengthy outdoor storage to minimize breakdown of mill scale and consequent rusting.

2.9.2 Paint Application

2.9.2.1 General

The finished coating shall be free from holidays, pinholes, bubbles, runs, drops, ridges, waves, laps, excessive or unsightly brush marks, and variations in color, texture, and gloss. Application of initial or subsequent coatings shall not commence until the Contracting Officer has

SECTION 41 24 26 Page 12 verified that atmospheric conditions and the surfaces to be coated are satisfactory. Each paint coat shall be applied in a manner that will produce an even, continuous film of uniform thickness. Edges, corners, crevices, seams, joints, welds, rivets, corrosion pits, and other surface irregularities shall receive special attention to ensure that they receive an adequate thickness of paint. Spray equipment shall be equipped with traps and separators and where appropriate, mechanical agitators, pressure gauges, pressure regulators, and screens or filters. Air caps, nozzles, and needles shall be as recommended by the spray equipment manufacturer for the material being applied. Airless-type spray equipment may be used only on broad, flat, or otherwise simply configured surfaces, except that it may be employed for general painting if the spray gun is equipped with dual or adjustable tips of proper types and orifice sizes.

2.9.2.2 Mixing and Thinning

Paints shall be thoroughly mixed, strained where necessary, and kept at a uniform composition and consistency during application. Where necessary to suit conditions of the surface temperature, weather, and method of application, the paint may be thinned immediately prior to use in strict accordance with the manufacturer's instructions. Temperature of paint before being mixed and thinned, and its temperature in the spray tank or other working container shall be as specified by the manufacturer. Paint and thinner that is more than 1 year old shall be resampled and resubmitted for testing to determine its suitability for application.

2.9.2.3 Atmospheric and Surface Conditions

Paint shall be applied only to surfaces that are above the dew point temperature and that are completely free of moisture as determined by sight and touch. Paint shall not be applied to surfaces upon which there is detectable frost or ice. Except as otherwise specified, the temperature of the surfaces to be painted and of air in contact therewith shall be not less than 45 degrees F during paint application nor shall paint be applied if the surfaces can be expected to drop to 32 degrees F or lower before the film has dried to a reasonably firm condition. During periods of inclement weather, painting may be continued by enclosing the surfaces and applying artificial heat, provided the minimum temperatures and surface dryness requirements prescribed previously are maintained.

Paint shall not be applied to surfaces heated by direct sunlight or other sources to temperatures that will cause detrimental blistering, pinholing, or porosity of the film.

2.9.2.4 Time Between Surface Preparation and Painting

Surfaces that have been cleaned and/or otherwise prepared for painting shall be primed as soon as practicable after such preparation has been completed but, in any event, prior to any deterioration of the prepared surface.

2.9.2.5 Method of Paint Application

Unless otherwise specified, paint shall be applied by brush or spray.

Special attention shall be directed toward ensuring adequate coverage of edges, corners, crevices, pits, welds, and similar surface irregularities. Other methods of application to metal surfaces shall be subject to the specific approval of the Contracting Officer.

SECTION 41 24 26 Page 13

2.9.2.6 Coverage and Film Thickness

Film thickness or spreading rates shall be as specified hereinafter.

Where no spreading rate is specified, the paint shall be applied at a rate normal for the type of material being used. In any event, the combined coats of a specified paint system shall completely hide base surface and the finish coats shall completely hide undercoats of dissimilar color.

2.9.2.6.1 Measurement on Ferrous Metal

Where dry film thickness requirements are specified for coatings on ferrous surfaces, measurements shall be made with a gage qualified in accordance with paragraph Coating Thickness Gage Qualification. They shall be calibrated and used in accordance with ASTM D7091. Prior to each use the Base Metal Reading (BMR) shall be established for the gage as specified in the test method. Accuracy of the gage shall be verified using plastic shims as specified by the test method both prior to and following each set of measurements. Frequency of measurements shall be as recommended for field measurements by ASTM D7091, except that measurements shall be performed on all areas of the structure being coated. Thickness measurements shall be reported as the mean for each spot determination.

2.9.2.7 Progress of Painting Work

Where field painting on any type of surface has commenced, the complete painting operation, including priming and finishing coats, on that portion of the work shall be completed as soon as practicable, without prolonged delays. Sufficient time shall elapse between successive coats to permit them to dry properly for recoating, and this period shall be modified as necessary to suit adverse weather conditions. Paint shall be considered dry for recoating when it feels firm, does not deform or feel sticky under moderate pressure of the finger, and the application of another coat of paint does not cause film irregularities such as lifting or loss of adhesion of the undercoat. All coats of all painted surfaces shall be unscarred and completely integral at the time of application of succeeding coats. At the time of application of each successive coat, undercoats shall be cleaned of dust, grease, overspray, or foreign matter by means of airblast, solvent cleaning, or other suitable means. Field coats on metal shall be applied after erection except as otherwise specified and except for surfaces to be painted that will become inaccessible after erection.

2.9.2.8 Protection of Painted Surfaces

Where shelter and/or heat are provided for painted surfaces during inclement weather, such protective measures shall be maintained until the paint film has dried and discontinuance of the measures is authorized.

Items that have been painted shall not be handled, worked on, or otherwise disturbed until the paint coat is fully dry and hard. All metalwork coated in the shop or field prior to final erection shall be stored out of contact with the ground in a manner and location that will minimize the formation of water-holding pockets; soiling, contamination, and deterioration of the paint film, and damaged areas of paint on such metalwork shall be cleaned and touched up without delay. The first field coat of paint shall be applied within a reasonable period of time after the shop coat and in any event before weathering of the shop coat becomes extensive.

SECTION 41 24 26 Page 14

2.9.3 Paint Systems Application

The required paint systems and the surfaces to which they shall be applied are shown in this paragraph. Supplementary information follows.

2.9.3.1 Surface Preparation

The method of surface preparation and pretreatment shown in the tabulation of paint systems is for identification purposes only. Cleaning and pretreatment of surfaces prior to painting shall be accomplished in accordance with detailed requirements specified in paragraph "CLEANING AND

PREPARATION OF SURFACES TO BE PAINTED".

2.9.3.2 System No. 23-D

The coating system shall be applied according to the manufacturer's written instructions. It shall be a 3-coat system. All materials shall be procured from the same coating manufacturer. The individual paints comprising the system shall have been tested and passed all the requirements of the applicable SSPC standards. Application shall be by spray, brush, or roller. Dry film thickness per coat shall be that recommended by the manufacturer. Application of the system in less than three coats shall not be accepted. The coatings shall be mixed and thinned in accordance with the manufacturers written directions. Coating material that has exceeded the manufacturer's pot life shall not be applied. Materials that have thickened appreciably shall not be applied.

The manufacturer's recommendations for minimum and maximum dry time between coats shall be met. Areas of bubbling noted upon curing of any individual coat shall be removed by sanding or screening. The edges of the repaired areas shall be feathered and the coat reapplied to the repaired areas before a subsequent coat is applied.

2.9.4 Painting Schedule

SYSTEM NO. 23-D Alternate 2

Items or surfaces to be coated: Conductor Rail Maintenance Platform

SURFACE PREPARATION 1st COAT 2nd COAT 3rd COAT

Commercial Blast Clean (shop) or Power Tool Clean (field touchup)

SSPC Paint 41 SSPC Paint 41 Finish color:

SSPC Paint 41 Finish color:

2.9.4.1 Finish Colors

The Contractor shall submit a sample of all colors to the Contracting Officer for approval before ordering paint. The finish color shall be approximately the same color as the piping and equipment.

3.7 Inspection

The Contractor shall inspect, document, and report all work phases and operations on a daily basis. As a minimum the daily inspection and operation records shall contain the following:

a. Inspections performed, including the area of the structure

SECTION 41 24 26 Page 15 involved and the results of the inspection.

b. Surface preparation operations performed, including the area of the structure involved, the mode of preparation, the kinds of solvent, abrasive, or power tools employed, and whether contract requirements were met.

c. Thinning operations performed, including thinners used, batch numbers, and thinner/paint volume ratios.

d. Application operations performed, including the area of the structure involved, mode of application employed, ambient temperature, substrate temperature, dew point, relative humidity, type of paint with batch numbers, elapsed time between surface preparation and application, elapsed time for recoat, condition of underlying coat, number of coats applied, and if specified, measured dry film thickness or spreading rate of each new coating.

A sample paint inspection report form is attached at the end of this Section of the specifications. Temperature shall be recorded from the noted areas to portray the minimum and maximum range of temperature. The Contractor's quality control inspectors shall sign and date sheet after he has inspected the surface preparation paint coating and is assured of its adequacy. The record of the above data shall be submitted to the Contracting Officer in accordance with paragraph "SUBMITTALS".

PART 3 EXECUTION

3.1 EXAMINATION

After becoming familiar with all details of the work, verify dimensions in the field and advise the Contracting Officer of any discrepancy before performing the work.

3.2 INSTALLATION

Installation of hydraulic components shall be in accordance with the manufacturer's written instructions and under the direction of the hydraulics technician. Complete units or assemblies shall be installed without disassembly. Necessary supports for all appurtenances or components shall be provided. All valves and other fluid control devices shall be mounted as indicated. Mounting subplates shall be installed on rigid supporting surfaces in a manner that will preclude imposition of forces on the piping and tubing other than those created by fluid pressure alone. Shims shall be provided at locations required to permit proper adjustment, alignment, and position of system components and assemblies.

Components shall be marked to indicate pertinent operational requirements, warnings, and limitations such as maximum allowable operating pressure, temperature, velocity, range of adjustment, flow capacity, stroke, direction of flow, rotation or motion, safety precautions, and materials compatibility. The markings shall be by stamping or embossing on the component or on an attached plate or tag which shall, barring mutilation, remain affixed and legible for the life of the component.

3.2.1 Installation Drawing Submittal

Submit drawings consisting of a complete list of equipment and materials, including manufacturer's descriptive and technical literature; catalog cuts; performance charts and curves; and installation instructions.

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Drawings shall also contain complete wiring and schematic diagrams and other details required to demonstrate that the system has been coordinated and will properly function as a unit. Drawings for motors, actuators, cylinders, pumps, controls, and other components shall be included.

Moving parts fluid control diagrams shall follow the methods in NFLPA T3.28.9 . Drawings shall show proposed layout and anchorage of equipment and appurtenances, and equipment relationship to other parts of the work including clearances required for maintenance and operation.

Details shall include loadings and types of frames, brackets, stanchions and other supports, and pipe anchors for supported pipe and equipment.

Foundation drawings shall include bolt setting information for equipment indicated or required to have concrete foundations.

3.2.2 Components and Subassemblies

Components shall be securely mounted to the supporting surface. Care shall be exercised that fastenings are not overtightened to the extent that component bodies are distorted or damaged. Pivot type mountings shall be carefully aligned to ensure free operation throughout the entire range of movement. Subassemblies shall be mounted and braced independently of the connecting lines.

3.2.3 Rigid Conductors

Hydraulic pipe and tubing shall be securely mounted and anchored to structural members. Supports and anchors shall be located as indicated.

Seals shall not be removed from pipe and tubing assemblies or from ports on components until the lines are ready for connection. Provisions, including but not limited to providing portable screens and shelters, shall be taken to minimize the entrance of abrasives, dirt, metal chips, and other foreign materials into the hydraulic system through open ends of lines and ports of components.

3.2.4 Flexible Conductors

Flexible conductors shall be installed in accordance with the manufacturer's recommendations. Special care shall be exercised to avoid imparting any twist in the conductors during tightening of fittings.

Supports shall be provided and located to prevent conductors from contacting and chafing against fixed members. Clamps and straps used to support hoses shall be provided with soft resilient sleeves, linings or bushings to prevent cutting and abrading of the hose. The routing of flexible hoses shall be arranged to preclude imparting a twist in the hose due to relative motion between the components to which the hose is connected. The minimum bend radius of the hose shall not be less than that recommended for the particular hose size and maximum system operating pressure. Heat shields or insulating jackets shall be provided where hose passes close to heated surfaces.

3.2.5 Welded Installation

Hydraulic pipe weldments shall be as indicated. Changes in direction of piping shall be made with welding fittings only; mitering or notching pipe to form elbows and tees or other similar type construction will not be permitted. Branch connection may be made with either welding tees or forged branch outlet fittings. Branch outlet fittings shall be forged, flared for improvement of flow where attached to the run, and reinforced against external strains. Beveling, alignment, heat treatment, and inspection of welds shall conform to ASME B31.1 . Weld defects shall be

SECTION 41 24 26 Page 17 removed and repairs made to the weld, or the weld joints shall be entirely removed and rewelded at no additional cost to the Government. After filler metal has been removed from its original package, it shall be protected or stored so that its characteristics or welding properties are not adversely affected. Electrodes that have been wetted or that have lost any of their coating shall not be used.

3.2.6 Special Considerations

The Contractor is required to remove portions of the hydraulic system for the installation of the new piping and controls. This work will require coordination with lock personnel to minimize impact on daily operations at the lock and to maintain the lock chamber in operation. The Contractor shall coordinate their work with lock personnel as directed by the Contracting Officer.

3.3 MANUFACTURERS' FIELD SERVICES

Provide services of a manufacturer's representative who is experienced in the installation, adjustment, and operation of the equipment specified.

The representative shall supervise the installation, adjustment and tests of equipment.

3.3.1 Hydraulic Technician

Provide services of a hydraulics technician to coordinate and supervise the installation, adjustments, tests, and field instructions for the hydraulic system. The hydraulics technician shall have at least 3 years of current experience in the installation and operation of similar systems and shall be recommended by the system supplier or may be the manufacturer's representative.

3.3.2 Field Instructions Preparation

Submit proposed diagrams, instructions, and other sheets, before posting.

Wiring and control diagrams showing the complete layout of the entire system including equipment piping, valves, and control sequence, framed under glass or in laminated plastic, shall be posted where indicated for local operator and maintenance assistance. In addition, condensed operating instructions explaining preventive maintenance procedures, methods of checking the system for normal safe operation, and procedures for safely starting and stopping the system shall be typed, framed as specified for the wiring and control diagrams, and posted beside the diagrams. Post the framed instructions before acceptance testing of the systems.

3.4 FIELD TESTS AND CLEANING OF HYDRAULIC LINES

Secure the services of a hydraulic engineer or technician, as approved by the Contracting Officer, to monitor the final cleaning and testing of the hydraulic system.

a. Submit test reports in booklet form showing field tests performed to adjust each component and field tests performed to prove compliance with the specified performance criteria, upon completion and testing of the installed system. Indicate in each test report the final position of any system controls.

b. As a portion of the cleaning procedure, submit details of the sampling

SECTION 41 24 26 Page 18 and testing operations and the possible locations for withdrawing hydraulic fluid samples.

3.4.1 Field Training

Provide a field training course for designated operating staff members.

Training shall be provided for a total period of 2 hours of normal working time and shall start after the system is functionally complete but prior to final acceptance tests. Field training shall cover items contained in the Operation and Maintenance Manuals.

3.4.1.1 Operation Manual

Submit operating instructions outlining the step-by-step procedures required for system startup, operation, and shutdown. The instructions shall include the manufacturer's name, model number, service manual, parts list, and brief description of all equipment and their basic operating features. Field cleaning procedures designed to clean the system to the requirements specified.

3.4.1.2 Maintenance Manual

Submit maintenance instructions listing routine maintenance procedures, possible breakdowns and repairs, and troubleshooting guides. The instructions shall include equipment layout and simplified wiring and control diagrams of the system as installed.

3.4.2 Hydraulic System Final Acceptance Tests

3.4.2.1 Preparation

In preparation for the final acceptance tests, and after completion of installation, lubrication, and adjustment, operate the hydraulic system to prove acceptability. Complete this test not less than 10 days before final acceptance tests. Conduct preliminary tests at minimum pressures and velocities until initial adjustments have been proven safe for normal operation. Details of all operations shall be constantly monitored for signs of impending trouble and corrections made as necessary to prevent damage to equipment.

3.4.2.2 Conducting Final Acceptance Tests

At such time as the Contracting Officer may direct, conduct the following complete acceptance tests on the hydraulic system for approval. All tests shall be conducted in the presence of the Contracting Officer. Each deficiency or maladjustment disclosed by the tests shall be corrected immediately and the test repeated until satisfactory results are obtained. No subsequent tests will be permitted until all preceding tests have been completed satisfactorily.

3.4.2.2.1 Initial Start-Up

The hydraulic reservoirs shall be inspected to ensure that fluid is at the proper level. The hydraulic pumps shall be started using the controls at the control console. Hydraulic lines and components which are under pressure shall be inspected for evidence of leakage and for evidence of distortion because of inadequate or improper support.

SECTION 41 24 26 Page 19

3.4.2.2.2 Combined System Tests

Tests and inspections of each branch of the hydraulic system shall be performed concurrently with the testing specified under other sections which test the mechanism operated by the hydraulic system. Each cylinder shall be tested 3 times through the interlock sequence shown in the electrical drawings to determine compliance. During each test operation hydraulic lines and devices shall be inspected for leakage and for evidence of distortion due to inadequate or improper support. Manual overrides shall be tested to validate functionality. The pressure in the supply and return lines for each direction of operation shall be read (where practicable) and recorded. Response of components to operation of applicable controls shall be inspected to ensure that all connections have been made properly. Chokes in pilot circuits of pilot-operated valves shall be adjusted to obtain smooth, shock-free operation.

3.4.2.2.3 Test Logs

Prepare and complete a test log showing in detail the results of the tests. Three copies of the completed test log shall be delivered to the Contracting Officer not more than 48 hours after completion of the tests.

Prepare a complete and detailed tabulation showing values of pressures, flow rates, and all adjustments recorded during final tests, adjustment, and calibration of the entire system. During each test run, the following data and observations shall be recorded:

a. Control operation

b. Voltages

c. Currents

d. Hydraulic pressures

e. Speeds and times

f. Alignment and operating clearances

g. Excessive vibration, by component

h. Temperature of motors and hydraulic fluid

i. Pertinent observations regarding such events as unusual sounds, malfunctions or difficulties encountered, and adjustments required.

3.5 PAINTING AND COLOR CODING

3.5.1 Painting

All exposed exterior surfaces of assemblies and equipment except corrosion-resistant steel, synthetic rubber, and plastic, shall be shop primed and coated as specified: Complete system, including color coding and piping, shall be painted as specified in paragraph PAINTING. Insofar as practicable, the complete coating system shall be applied to individual components and items before assembly to ensure complete coverage and maximum protection against corrosion.

SECTION 41 24 26 Page 20

3.5.2 Field Touch-Up

Chips, scratches, and other damage to shop-applied painted surfaces shall be repainted in the field. Finish field colors shall match those of marred finishes.

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