B.08.03 W912EF20R0007 Amendment 04 Technical Specifications.pdf

Dworshak RO Valves Upgrade W912EF20R0007

PROJECT TABLE OF CONTENTS

DIVISION 00 - PROCUREMENT AND CONTRACTING REQUIREMENTS

00 01 15.00 28 LIST OF DRAWINGS

DIVISION 01 - GENERAL REQUIREMENTS

01 00 00.00 28 GENERAL REQUIREMENTS

01 11 01.00 28 SUPPLEMENTARY REQUIREMENTS

01 14 00.10 28 PROJECT SITE RESTRICTIONS

01 14 00.90 28 INTEGRATING ANTITERRORISM (AT) AND OPERATIONS SECURITY

(OPSEC)

01 22 00.00 28 MEASUREMENT AND PAYMENT

01 32 01.00 28 PROJECT SCHEDULE

01 33 00 SUBMITTAL PROCEDURES

01 35 29.10 28 GOVERNMENTAL SAFETY REQUIREMENTS

01 42 00 SOURCES FOR REFERENCE PUBLICATIONS

01 45 01.00 28 RESIDENT MANAGEMENT SYSTEM CONTRACTOR MODE (RMS CM)

01 45 04.00 28 CONTRACTOR QUALITY CONTROL

01 51 00.00 28 TEMPORARY UTILITIES

01 55 10.00 28 CONTRACTOR WORK, ACCESS AND STORAGE AREAS

01 57 20.00 28 ENVIRONMENTAL PROTECTION

01 78 00.00 28 CLOSEOUT SUBMITTALS

01 78 23.00 28 OPERATION AND MAINTENANCE DATA

DIVISION 02 - EXISTING CONDITIONS

02 41 00.00 28 DEMOLITION

02 83 33.13 28 TOXIC METALS BASED PAINT REMOVAL AND DISPOSAL

DIVISION 03 - CONCRETE

03 01 32 CONCRETE REHABILITATION FOR CIVIL WORKS

03 30 10.01 28 MISCELLANEOUS CONCRETE

03 60 00 CEMENTITIOUS GROUT

DIVISION 05 - METALS

05 50 15 CIVIL WORKS FABRICATIONS

DIVISION 09 - FINISHES

09 97 02 PAINTING: HYDRAULIC STRUCTURES

DIVISION 25 - INTEGRATED AUTOMATION

25 05 11.00 28 CYBERSECURITY

DIVISION 26 - ELECTRICAL

26 00 00.00 20 BASIC ELECTRICAL MATERIALS AND METHODS

26 05 00.00 40 COMMON WORK RESULTS FOR ELECTRICAL

26 05 19.00 10 INSULATED WIRE AND CABLE

26 24 16.00 40 PANELBOARDS

DIVISION 27 - COMMUNICATIONS

27 13 23.00 40 COMMUNICATIONS OPTICAL BACKBONE CABLING

PROJECT TABLE OF CONTENTS Page 1

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

35 05 40.14 10 HYDRAULIC POWER SYSTEMS FOR CIVIL WORKS STRUCTURES

35 20 20 ELECTRICAL EQUIPMENT FOR HYDRAULIC POWER SYSTEMS

DIVISION 40 - PROCESS INTERCONNECTIONS

40 95 00 PROCESS CONTROL EQUIPMENT

-- End of Project Table of Contents --

PROJECT TABLE OF CONTENTS Page 2

SECTION TABLE OF CONTENTS

DIVISION 00 - PROCUREMENT AND CONTRACTING REQUIREMENTS

SECTION 00 01 15.00 28

LIST OF DRAWINGS

PART 1 GENERAL

1.1 SUMMARY

1.2 CONTRACT DRAWINGS

1.2.1 Use Of Government Prepared Contract CAD Electronic Files

1.3 RESOURCE DRAWINGS (R)

-- End of Section Table of Contents --

DOCUMENT 00 01 15.00 28 Page 1

SECTION 00 01 15.00 28

LIST OF DRAWINGS

PART 1 GENERAL

1.1 SUMMARY

This section lists the drawings for the project pursuant to contract clause "DFARS 252.236-7001, Contract Drawings, Maps and Specifications."

1.2 CONTRACT DRAWINGS

Contract drawings are as follows:

SHEET

NUMBER

FILE NUMBER DESCRIPTION Revision Number

Date

GENERAL

G-001 DWG-1-0-1/474 COVER SHEET AND LOCATION MAPS

G-002 DWG-1-0-1/475 INDEX TO DRAWINGS 1 7/24/20

G-003 DWG-1-0-1/476 STANDARD SYMBOLS, STANDARD

ABBREVIATIONS

G-004 DWG-1-0-1/477 OVERALL ARRANGEMENT AND WORK

ELEMENTS

1 7/29/20

STRUCTURAL

S-100 DWD-1-5-17/41 EXISTING KEY PLAN AND OVERALL

PLAN AT OUTLET WORKS

S-101 DWD-1-5-17/42 EXISTING OVERALL SECTION THRU

RO #2

S-102 DWD-1-5-17/43 EXISTING GATE CHAMBER GENERAL

ARRANGEMENT

S-103 DWD-1-5-17/44 TYPICAL EMERGENCY GATE

LEAKAGE PHOTOS

S-104 DWD-1-5-17/45 RO VALVE EMBEDDED SEALING

SURFACE REPAIRS PLAN AND

SECTION

S-105 DWD-1-5-17/46 RO VALVE EMBEDDED SEALING

SURFACE REPAIRS SECTIONS AND

DETAILS 1

S-106 DWD-1-5-17/47 RO VLAVE EMBEDDED SEALING

SURFACE REPAIRS SECTIONS AND

DETAILS 2

S-107 DWD-1-5-17/48 EXISTING RO CONDUIT CONCRETE

REPAIR GENERAL ARRANGEMENT

DOCUMENT 00 01 15.00 28 Page 2

G4EDDMTJ

Line

G4EDDMTJ

Line

S-108 DWD-1-5-17/49 RO CONDUIT CONCRETE REPAIR

SCHEDULES

S-109 DWD-1-5-17/50 RO CONDUIT CONCRETE REPAIR

DETAILS SHT 1 OF 2

S-110 DWD-1-5-17/51 RO CONDUIT CONCRETE REPAIR

DETAILS SHT 2 OF 2

S-111 DWD-1-5-17/52 MONOLITHS 17 THROUGH 20 PLAN

AND SECTIONS

MECHANICAL

M-001 DWD-1-3-17/18 HYDRAULIC SYSTEM MECHANICAL

EQUIPMENT SCHEDULE

1 7/23/20

MD-101DWD-1-3-17/19 MACHINERY ROOM DEMOLITION PLAN

MD-102DWD-1-3-17/20 GATE CHAMBER DEMOLITION PLAN

M-100 DWD-1-3-17/21 HYDRAULIC SYSTEM GENERAL

ARRANGEMENT

1 8/4/20

M-101 DWD-1-3-17/22 HYDRAULIC SCHEMATIC

M-102 DWD-1-3-17/23 HYDRAULIC PIPING PLAN

M-103 DWD-1-3-17/24 STANDARD MECHANICAL DETAILS

M-104 DWD-1-3-17/25 HYDRAULIC PIPING SECTIONS

M-105 DWD-1-3-17/26 VALVE OPERATING CYLINDER PLAN 1 7/24/20

M-106 DWD-1-3-17/27 VALVE OPERATING CYLINDER

CONNECTION DETAILS

M-107 DWD-1-3-17/28 ECCENTRIC CYLINDER PLAN 1 7/24/20

M-108 DWD-1-3-17/29 ECCENTRIC SHAFT AND BEARINGS

PLAN 1

M-109 DWD-1-3-17/30 ECCENTRIC SHAFT AND BEARINGS

PLAN 2

M-110 DWD-1-3-17/31 OPERATING CYCLINDER SUPPORT

FRAME MODIFICATIONS

1 7/29/20

M-111 DWD-1-3-17/32 ECCENTRIC CYLINDER SUPPORT

ELECTRICAL

E-001 DWD-1-6-17/1 ELECTRICAL ABBREVIATIONS AND

SYMBOLS

E-101 DWD-1-6-17/2 ELECTRICAL PLAN

E-102 DWD-1-6-17/3 DAM ELECTRICAL ROOM

ELECTRICAL PLAN

E-103 DWD-1-6-17/4 POWERHOUSE ELECTRICAL PLAN

DOCUMENT 00 01 15.00 28 Page 3

G4EDDMTJ

Line

G4EDDMTJ

Line

G4EDDMTJ

Line

G4EDDMTJ

Line

E-104 DWD-1-6-17/5 CONDUIT SCHEDULE

E-105 DWD-1-6-17/6 CABLE SCHEDULE

E-106 DWD-1-6-17/7 GENERAL CABLE ROUTING PLAN

E-201 DWD-1-6-17/8 RO CONTROLLER FRONT PANEL

ELEVATION

E-202 DWD-1-6-17/9 RO CONTROLLER INTERNAL PANEL

LAYOUT

E-203 DWD-1-6-17/10 RO CONTROLLER CONTROL

SCHEMATIC SHEET 1 OF 2

E-204 DWD-1-6-17/11 RO CONTROLLER CONTROL

SCHEMATIC SHEET 2 OF 2

E-205 DWD-1-6-17/12 RO CONTROLLER REMOTE PLC

CHASSIS I/O SLOT 2 DIGITAL

OUTPUT

E-206 DWD-1-6-17/13 RO CONTROLLER REMOTE PLC

CHASSIS I/O SLOT 3 AND 4

E-207 DWD-1-6-17/14 RO CONTROLLER REMOTE PLC

CHASSIS I/O SLOT 5 ANALOG

INPUT

E-301 DWD-1-6-17/15 MASTER STATION SERVICE PLC

CONFIGURATION

E-302 DWD-1-6-17/16 MASTER STATION SERVICE PLC

REMOTE RO PLC CHASSIS

CONFIGURATION

E-400 DWD-1-6-17/17 HYDRAULIC ACTUATORS P&ID

DIAGRAM STANDARD SYMBOLS

E-401 DWD-1-6-17/18 HYDRAULIC ACTUATORS P&ID

DIAGRAM

1.2.1 Use Of Government Prepared Contract CAD Electronic Files

a. No For Information Only drawings are available on CAD.

b. The Contractor assumes all risks associated in using electronic CAD drawings.

c. Electronic copies of CAD drawings are only available in Bentley DGN format.

d. The contract drawings shall govern if there are any discrepancies between the electronic copy and the contract drawing. The Contractor shall promptly notify the Contracting Officer of any discrepancies.

The Government will not be responsible to correct the electronic CAD drawing.

1.3 RESOURCE DRAWINGS (R)

These R drawings are included with the drawings for information only. The Government does not warrant the accuracy of the R drawings. The Government

DOCUMENT 00 01 15.00 28 Page 4 recommends that the Contractor verify the accuracy of R drawings.

Resource (R) drawings are as follows:

SHEET

NUMBER

FILE NUMBER DESCRIPTION Revision Number

Date

R-001 DWD-1-0-1/8 GENERAL - ISOMETRIC VIEW OF

GALLERIES IN MONOLITHS 14 THRU 37

R-002 DWD-1-4-2/15 CONCRETE OUTLINE - MONOLITHS 16

THRU 20 - PLAN AND ELEVATION I

R-003 DWD-1-4-2/16 CONCRETE OUTLINE - MONOLITHS 16

THRU 20 - PLAN AND ELEVATION II

R-004 DWD-1-4-2/17 CONCRETE OUTLINE - MONOLITHS 16

THRU 20 - SECTIONS

R-005 DWD-1-4-17/25 OUTLET WORKS - AIR VENT - PLAN AND

SECTION

R-006 DWD-1-4-17/29 OUTLET WORKS - VALVE ROOM - PLANS

AND DETAILS

R-007 DWD-1-4-17/30 OUTLET WORKS - VALVE ROOM - SECTIONS

R-008 DWD-1-5-17/7 OUTLET WORKS - TAINTER VALVE -

ELEVATION, SECTIONS & DETAILS

R-009 DWD-1-5-17/9 OUTLET WORKS - TAINTER VALVE

GUIDES - ELEVATION, SECTION AND

DETAILS

R-010 DWD-1-4-17/31 OUTLET WORKS - VALVE ROOM - DETAILS

& SECTIONS

R-011 DWD-1-4-17/32 OUTLET WORKS - VALVE ROOM -

REINFORCEMENT SECTIONS I

R-012 DWD-1-4-17/32.1OUTLET WORKS - CONDUIT -

REINFORCEMENT

R-013 DWD-1-4-17/33 OUTLET WORKS - VALVE ROOM -

REINFORCEMENT SECTIONS II

R-014 DWD-1-4-17/34 OUTLET WORKS - VALVE ROOM -

REINFORCEMENT SECTIONS III

R-015 14636-1 ECCENTRIC TRUNNION - ASSEMBLY

R-016 14636-2 ECCENTRIC TRUNNION - ASSEMBLY

R-017 14640 ECCENTRIC TRUNNION - CYLINDER

SUPPORT ASS'Y

R-018 14644 CYLINDER SUPPORT - WELDMENT

R-019 14658 ECCENTRIC TRUNNION - SEAL RETAINER

- GASKET

DOCUMENT 00 01 15.00 28 Page 5

R-020 14659 ECCENTRIC TRUNNION - BEARING

HOUSING

R-021 14660-1 ECCENTRIC TRUNNION - PILLOW BLOCK

R-022 14660-2 ECCENTRIC TRUNNION - PILLOW BLOCK

R-023 14661 ECCENTRIC TRUNNION - SHAFT

R-024 DWD-1-4-4/4 SPILLWAY - ABUTMENT PIER MONOLITH

20 - 1573 GALLERY AND DETAILS

R-025 DWD-1-4-3/2 SPILLWAY - MONOLITHS 18, 19 AND 20

- REINFORCEMENT DETAILS

R-026 DWD-1-4-3/1 SPILLWAY - MONOLITHS 18, 19 AND 20

- 1614.04 DECK REINFORCEMENT

R-027 DWD-1-4-4/5 SPILLWAY - MONOLITHS 18, 19 AND 20

- PIER REINFORCEMENT

R-028 DWD-1-4-4/6 SPILLWAY - ABUTMENT PIER MONOLITH

18 - REINFORCEMENT

R-029 DWD-1-4-4/8 SPILLWAY - ABUTMENT PIER MONOLITH

20 - REINFORCEMENT

R-030 DWD-1-4-4/9 SPILLWAY - ABUTMENT PIER MONOLITH

20 - REINFORCEMENT AND DETAILS

R-031 DWD-1-4-2/58 SHAFTS - ROOMS - GALLERIES - 1603

GALLERY TYPICAL REINFORCEMENT

R-032 DWD-1-3-17/4 ECCENTRIC OPERATOR ASSUMBLY

CYLINDER SUPPORTS

R-033 DWD-1-3-17/6 ECCENTRIC TRUNNION ASSEMBLY DETAILS

R-034 DWD-1-3-17/7 POSITION INDICATOR ASSEMBLY DETAILS

-- End of Document --

DOCUMENT 00 01 15.00 28 Page 6

SECTION TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

SECTION 35 05 40.14 10

HYDRAULIC POWER SYSTEMS FOR CIVIL WORKS STRUCTURES

PART 1 GENERAL

1.1 SUMMARY

1.2 REFERENCES

1.3 DESIGN AND PERFORMANCE REQUIREMENTS AND CALCULATIONS

1.3.1 Design Parameters

1.3.2 Allowable Stresses

1.3.2.1 Structural Items

1.3.2.2 Hydraulic Cylinders

1.3.2.3 Stress Concentration Factors

1.3.3 Connections

1.3.3.1 Pinned Connections

1.3.3.2 Shop Connections

1.3.3.3 Structural Bolted Connections

1.3.4 Hydraulics Design Criteria

1.4 SUBMITTALS

1.5 SCHEMATIC DRAWINGS AND DATA

1.5.1 Shop Drawings

1.5.2 Fabrication Drawings

1.5.3 Hydraulic Power Unit Drawings

1.5.4 Manifold Drawings

1.5.5 Piping Drawings

1.5.6 Electrical Drawings

1.5.7 Shop Assembly Drawings

1.5.8 Hydraulic Schematic

1.5.9 Product Data

1.5.10 Delivery Drawings

1.5.11 Shop Assembly and Testing Procedures and Results

1.5.12 Field Installation Procedures

1.5.13 Design and Performance Requirements

1.5.14 Cleaning and Flushing Procedures and Results

1.5.15 Erecting Engineer Qualifications

1.5.16 Initial Configuration Report

1.5.17 Installation Verification Report

1.6 DELIVERY, STORAGE, AND HANDLING

1.6.1 Packaging

1.6.2 Shipping, Preservation, and Storage

1.7 WARRANTY

1.8 QUALITY CONTROL

PART 2 PRODUCTS

2.1 MATERIALS AND MECHANICAL EQUIPMENT

2.1.1 General

2.1.2 Standard Products

2.1.3 Hydraulic Cylinders

SECTION 35 05 40.14 10 Page 1

2.1.3.1 Cylinder Tubes

2.1.3.2 Cylinder Heads and Caps

2.1.3.3 Pistons

2.1.3.4 Piston Rods (Standard Design)

2.1.3.5 Rod Wiper/Scraper

2.1.3.6 Piston Rod Seals

2.1.3.7 Rod Seal Gland and Locking Device Flange

2.1.3.8 Rod Locking Device

2.1.3.9 Cylinder Instrumentation

2.1.4 Hydraulic Power Unit

2.1.5 Oil Reservoirs

2.1.5.1 Reservoir Heater

2.1.5.1.1 Heater Switch

2.1.5.1.2 High Temperature Switch

2.1.5.2 Magnetic Separators

2.1.5.3 Low Level Float Switches

2.1.5.4 Flexible Reservoir Breathers

2.1.5.5 Oil Level Gage

2.1.6 Pumps

2.1.7 Accumulators

2.1.8 Filters

2.1.9 Gauges

2.1.9.1 Pressure Gauges

2.1.9.2 Thermometer

2.1.10 Manifolds

2.1.11 Valves

2.1.11.1 Shut-Off Valves

2.1.11.2 Needle Valves

2.1.11.3 Solenoid Operated Control Valves

2.1.11.3.1 Solenoid Operated Proportional Throttle Valve

2.1.11.4 Pressure Relief Valves

2.1.11.5 Supply Spring Loaded Check Valves

2.1.11.6 Return Spring Loaded Check Valves

2.1.11.7 Bleeder Valves

2.1.11.8 Pressure Snubbers

2.1.11.9 Counterbalance Valve

2.1.12 Tubing

2.1.12.1 Tube Hangers and Supports

2.1.12.2 Sleeves and Wall Brackets

2.1.12.3 Pipe Penetration Seals

2.1.12.4 Hydraulic Tubing

2.1.12.5 Tube Fittings

2.1.12.6 Hose

2.1.13 Bolts, Nuts, and Washers

2.1.13.1 Carbon Steel Bolts and Nuts

2.1.13.2 Stainless Steel Bolts and Nuts

2.1.13.3 Flat Washers

2.1.14 Hydraulic Fluid (Environmentally Acceptable)

2.2 SHOP ASSEMBLY AND TESTING

2.2.1 Cylinder Tests

2.2.2 Hydraulic Power Units

2.3 MANUFACTURER PREPARATION BEFORE SHIPMENT

2.3.1 Flushing Hydraulic Cylinders

2.3.2 Flushing Hydraulic Power Unit

2.4 PAINTING

2.5 SPECIAL TOOLS

2.6 SPARE PARTS

PART 3 EXECUTION

SECTION 35 05 40.14 10 Page 2

Cross-Out

3.1 EXAMINATION

3.2 FACTORY ACCEPTANCE TESTING

3.2.1 Factory Acceptance Test Procedure

3.2.2 Factory Acceptance Test Report

3.3 INSTALLATION

3.3.1 Eccentric Shaft

3.4 POWER PIPING

3.4.1 Piping Installation

3.4.2 Piping Vents and Drains

3.4.3 Mounting Support for Manifolds

3.4.4 Identification of Piping and Valves

3.5 CLEANING AND FLUSHING

3.5.1 Flushing Piping

3.5.2 Flushing Manifolds and Hoses

3.6 FILLING AND BLEEDING THE SYSTEM

3.7 ERECTION ENGINEER

3.8 FIELD TESTS AND INSPECTIONS

3.8.1 Commissioning Test Procedure

3.8.2 Commissioning Test Report

3.8.3 Pipe Pressure Test

3.8.4 Final Acceptance Tests

3.8.4.1 Initial Start-Up

3.8.4.2 Combined System Tests

3.8.4.3 Test Reports and Procedures

3.9 CLEAN-UP

3.10 OPERATION AND MAINTENANCE

-- End of Section Table of Contents --

SECTION 35 05 40.14 10 Page 3

SECTION 35 05 40.14 10

HYDRAULIC POWER SYSTEMS FOR CIVIL WORKS STRUCTURES

PART 1 GENERAL

1.1 SUMMARY

The work covered by this section of the specifications consists of detailed requirements for the design, fabrication, shop assembly, testing, delivery, and installation of three hydraulic power systems for operation of the regulating outlet gates at Dworshak Dam as specified and as shown.

1.2 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 B40.100 (2013) Pressure Gauges and Gauge Attachments

ASME BPVC SEC VIII D1 (2017) BPVC Section VIII-Rules for Construction of Pressure Vessels Division 1

ASTM INTERNATIONAL (ASTM)

ASTM A108 (2013) Standard Specification for Steel Bar, Carbon and Alloy, Cold-Finished

ASTM A193/A193M (2017) Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service and Other Special Purpose Applications

ASTM A194/A194M (2018) Standard Specification for Carbon Steel, Alloy Steel, and Stainless Steel Nuts for Bolts for High-Pressure or High-Temperature Service, or Both

ASTM A269/A269M (2015a; R 2019) Standard Specification for Seamless and Welded Austenitic Stainless Steel Tubing for General Service

ASTM A325 (2014) Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength

ASTM A354 (2017; E 2017; E 2018) Standard Specification for Quenched and Tempered Alloy Steel Bolts, Studs, and Other Externally Threaded Fasteners

SECTION 35 05 40.14 10 Page 4

ASTM A516/A516M (2017) Standard Specification for Pressure Vessel Plates, Carbon Steel, for Moderate-and Lower-Temperature Service

ASTM A519 (2006) Standard Specification for Seamless Carbon and Alloy Steel Mechanical Tubing

ASTM A536 (1984; R 2014) Standard Specification for Ductile Iron Castings

ASTM A576 (2017) Standard Specification for Steel Bars, Carbon, Hot-Wrought, Special Quality

ASTM B505/B505M (2018) Standard Specification for Copper Alloy Continuous Castings

ASTM B584 (2014) Standard Specification for Copper Alloy Sand Castings for General Applications

ASTM D3951 (2015) Commercial Packaging

ASTM D5864 (2011) Standard Test Method for Determining Aerobic Aquatic Biodegradation of Lubricants or Their Components

ASTM F844 (2007a; R 2013) Washers, Steel, Plain (Flat), Unhardened for General Use

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 1219-1 (2012; Amd 1 2016) Fluid Power Systems and Components Graphic Symbols and Circuit Diagrams - Part 1: Graphic Symbols for Conventional Use and Data-Processing Applications

ISO 1219-2 (2012) Fluid Power Systems and Components Graphic Symbols and Circuit Diagrams - Part 2: Circuit Diagrams

ISO 4021 (1992) Hydraulic Fluid Power - Particulate Contamination Analysis - Extraction of Fluid Samples from Lines of an Operating System

ISO 4406 (2017) Hydraulic Fluid Power - Fluids - Method for Coding the Level of Contamination by Solid Particles

ISO 4407 (2002) Hydraulic Fluid Power - Fluid Contamination - Determination of Particulate Contamination by the Counting Method Using an Optical Microscope

ISO 4413 (2010) Hydraulic Fluid Power — General Rules and Safety Requirements for Systems and Their Components

SECTION 35 05 40.14 10 Page 5

ISO 5598 (2008) Fluid Power Systems and Components

- Vocabulary

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS

INDUSTRY (MSS)

MSS SP-58 (2018) Pipe Hangers and Supports - Materials, Design and Manufacture, Selection, Application, and Installation

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

SAE J517 (2017) Hydraulic Hose

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)

U.S. ENVIRONMENTAL PROTECTION AGENCY (EPA)

EPA 560/6-82-002 (1982) Guidelines and Support Documents for Environmental Effects Testing

1.3 DESIGN AND PERFORMANCE REQUIREMENTS AND CALCULATIONS

The contract drawings indicate the general arrangement of three hydraulic power systems for operation of the regulating outlet gates including, clearances necessitated by the structure or other equipment, maximum overall dimensions, and other pertinent features.

Contractor shall furnish the detailed design in conformity with ISO 4413, and the following design parameters. Identify design and dimensional changes necessary to satisfy the principal design parameters identified in the paragraph DESIGN PARAMETERS (below) as variations in the submittals.

Dimensions submitted that differ from those indicated and not otherwise constrained by the Design Parameters and physical limitations of installation are subject to approval.

1.3.1 Design Parameters

The principal design parameters for the hydraulic power system are as follows and were developed at the minimum operating temperature and utilizing the hydraulic fluid as specified:

1.3.2 Allowable Stresses

1.3.2.1 Structural Items

Design structural items associated with the hydraulic power system, such as support beams, to withstand the maximum force exerted by the hydraulic cylinder plus any dead loads with a factor of safety of 2 based on the yield strength of the materials involved.

1.3.2.2 Hydraulic Cylinders

Design all hydraulic cylinders to withstand a maximum operating pressure of 2000 psi and a maximum system pressure of 3000 psi with a factor of safety

SECTION 35 05 40.14 10 Page 6 of 5 based on the ultimate strength of the material or 2 based on the yield strength of the material.

1.3.2.3 Stress Concentration Factors

Use stress concentration factors where applicable. Reduction of allowable stresses to compensate for repeated cycles of loading is not required.

1.3.3 Connections

1.3.3.1 Pinned Connections

Design pinned hydraulic cylinder connections for field assembly as shown.

1.3.3.2 Shop Connections

Design shop connections for assembly by means of welding or by bolting.

1.3.3.3 Structural Bolted Connections

Make structural bolted connections carrying primary loads with ASTM A325 bolts.

1.3.4 Hydraulics Design Criteria

Design system pressure of 3000 psi Design operating pressure of 2000 psi Design flow rate for eccentric circuit - 24 gpm Design flow rate of main operating cylinder circuit - 24 gpm Accumulator capacity each circuit - 30 gallons Eccentric cylinder extend operating time = 64 seconds Main operating cylinder extend operating time - 100 seconds Maximum design extend load for main operating cylinder - 100,530 lb Maximum design extend load for eccentric cylinder - 100,530 lb Ambient temperature range 10 F to 110 F Hydraulic piping/tubing velocity - maximum 5 feet per second

1.4 SUBMITTALS

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

submittals having an "I" designation are for information only. A designation following the "G" or "I" 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

Schematic Drawings and Data; G AE

SD-03 Product Data

Materials and Mechanical Equipment; I AE Standard Products; G ME Design and Performance Requirements and Calculations; G AE Shop Assembly and Testing Procedures; G AE Installation Procedures; G AE Piping Installation; G ME Erecting Engineer Qualifications; G AE Cleaning and Flushing; G ME

SECTION 35 05 40.14 10 Page 7

SD-05 Design Data

Design Calculation Report; I AE

SD-06 Test Reports

Factory Acceptance Test Procedure; G AE Factory Acceptance Test Report; G AE Operational Test Reports; G AE Shop Tests; G AE Field Tests; I AE Initial Configuration Report; G AE Installation Verification Report; G AE Commissioning Test Procedure; G AE Commissioning Test Report; G AE Piston Rods (Standard Design); G AE

1.5 SCHEMATIC DRAWINGS AND DATA

1.5.1 Shop Drawings

Include fabrication, shop assembly, delivery, and field installation drawings in the detailed shop drawings. Detail any component part of fabricated items omitted on the shop drawings. If departures from the contract drawings are deemed necessary by the Contractor, submit details of such departures, including changes in related portions of the project and reasons thereof, with the shop drawings. Provide fabrication and assembly drawings to 1-1/2 inch = 1 foot-0 inch or larger scale.

Provide a Design Calculation Report with the following calculations: gate operating times, hydraulic cylinder/connection stresses, cylinder buckling, hydraulic power unit sump size, pipe/tubing burst strength, and motor horsepower requirements. Demonstrate that the design complies with design criteria for those items.

1.5.2 Fabrication Drawings

Provide fabrication drawings for all mechanical and structural parts or components, except those which are of standard manufacture. The drawings must show complete details of materials, tolerances, machined surface finishes, connections, and proposed welding sequences which differentiate shop welds and field welds. Provide detailed drawings of the drilled passages or the manifolds.

1.5.3 Hydraulic Power Unit Drawings

Provide drawings for hydraulic power units showing general arrangement of components and outline dimensions of unit. Identify all components on the drawings and provide sufficient information to determine whether the components proposed conform to the specifications.

1.5.4 Manifold Drawings

Provide fabrication drawings for all manifolds showing general arrangements outline dimensions, and drilling dimensions. Identify all components on the drawings and provide sufficient information to determine whether the components proposed conform to the specifications. Identify all port

SECTION 35 05 40.14 10 Page 8 configurations and connections.

1.5.5 Piping Drawings

Provide piping drawings showing the complete hydraulic system in schematic format identifying all items of equipment incorporated in the system.

Include details of all pipe supports including those for manifolds and on the hydraulic power unit.

1.5.6 Electrical Drawings

Provide electrical drawings of all electrical equipment as identified in Section 35 20 20.

1.5.7 Shop Assembly Drawings

Provide shop assembly drawings with details for connecting the adjoining fabricated components in the shop to ensure satisfactory field installation.

1.5.8 Hydraulic Schematic

Provide a complete hydraulic schematic in accordance with ISO 1219-1 and ISO 1219-2. Show all hydraulic components on the schematic, and indicate all setpoint and size parameters for each component.

1.5.9 Product Data

Include performance data and curves for pumps, motors and valves. Provide catalog cuts and outline dimensions for the pumps, motors, filters, heaters, thermostats, float switches, pressure transducer, switches, breathers, and all valves, valve controls and other accessories.

1.5.10 Delivery Drawings

Provide delivery drawings with descriptions of methods of delivering components to the site, including details for supporting fabricated components during shipping to prevent distortion or other damage.

1.5.11 Shop Assembly and Testing Procedures and Results

Provide procedures for shop testing and operating test for all testing outlined in paragraphs SHOP ASSEMBLY AND TESTING and FIELD TESTS AND INSPECTIONS. Submit operational test reports for all required shop testing and testing of equipment after installation. Provide records of all adjustments and final settings for all hydraulic components in the system.

This includes pump flow rates, operating times, relief settings, counterbalance valve adjustments, operating pressures at both the hydraulic power units and cylinder manifolds, flow level adjustments, filter differential switch settings, and other parameters as outlined in the paragraph TEST REPORTS.

1.5.12 Field Installation Procedures

Provide field installation drawings with a detailed description of the field installation procedures. Include the location and method of support of installation and handling equipment, the provisions to be taken to protect concrete and other work during installation, the method of

SECTION 35 05 40.14 10 Page 9 maintaining components in correct alignment, and the methods for installing other appurtenant items. Include dates and schedule of work. Submit methods and procedures to accelerate the sequence of work for approval.

1.5.13 Design and Performance Requirements

Provide design computations for all items which are designed by the Contractor.

1.5.14 Cleaning and Flushing Procedures and Results

Provide detailed procedure for the cleaning and flushing of hydraulic cylinders, piping, and power unit as outlined in paragraph CLEANING AND FLUSHING, not less than 30 days before start of operations. Provide test reports of the results of the flushing and of the oil used to fill the system.

1.5.15 Erecting Engineer Qualifications

Provide a resume for the on-site erecting engineer with details on experience and background in similar installations.

1.5.16 Initial Configuration Report

Provide a complete report that documents the original conditions and alignment/configuration of the existing equipment. This report shall provide adequate detail and measurement such that the Contractor can verify equipment re-installation matches the original conditions.

1.5.17 Installation Verification Report

Provide a complete report that demonstrates, with photos, measurements and alignments, that the equipment is reinstalled and configured in the same state as the equipment was in prior to disassembly.

1.6 DELIVERY, STORAGE, AND HANDLING

1.6.1 Packaging

Do not prepare the hydraulic power systems for shipment until they have been inspected and accepted for shipment at origin by the Contracting Officer, unless inspection has been waived in writing. Ship each hydraulic power system or subassembly completely assembled. The subassemblies are defined as the following:

a. Hydraulic cylinders. Each hydraulic cylinder subassembly consists of the hydraulic cylinder, rod locks, trunnion,, bushings, rod ends, and rod/trunnion pins.

b. Hydraulic power units

c. Piping assemblies

d. Accumulators and gas cylinders

e. Electrical equipment and instrumentation per Section 35 20 20

All equipment must fit in the elevator or be lowered down the vent shaft.

Vent shaft is 3 feet in diameter.

SECTION 35 05 40.14 10 Page 10

Provide the subassemblies with adequate protective pads, supports, and blocking and securely restrained to prevent distortion or damage to the painted surfaces in transit. Any loss or damage during shipment, including damage to the painted surfaces, is the Contractor's responsibility; replace or repair without cost to the Government. Pack all accessories and spare parts separately in containers plainly marked "ACCESSORIES ONLY," or "SPARE PARTS ONLY." Place a packing list, listing the contents of each container, in a moisture-proof envelope and securely fasten to the outside of the container. Standard commercial packaging in accordance with ASTM D3951 will be acceptable except where a different method or standard of packaging is specified.

1.6.2 Shipping, Preservation, and Storage

Packing, crating, cradles, etc., necessary to ensure safe shipment are the responsibility of the Contractor and become the property of the Government upon delivery of the equipment. The hydraulic cylinders must be filled with the specified hydraulic fluid, and make provisions to account for expansion and contraction of the oil during shipping and storage by installation of a bladder type accumulator to the rod end bleed port. Then securely cap remaining ports with blank flanges to prevent the entrance of foreign matter. Make provisions with external shipping devices to prevent damage to the cylinder and piston rod resulting from the rod flexing up and down in the cylinder during transport. Internal rod supports are not acceptable.

Submit a proposal for controlling movement of the piston rod for approval.

Adequately protect machined surfaces from corrosion and physical damage.

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

1.7 WARRANTY

All equipment must be guaranteed for a period of 2 years from the date of acceptance. Guarantee replacement parts for 2 years from date of replacement. Provide Warranty against defective materials, design, and workmanship. In cases where the equipment manufacturer's advertised minimum guarantee is in excess of 2 years, it remains in force for its full period. Upon receipt of notice from the Government of failure of any of the parts during the warranty period, provide new replacement parts promptly at no additional cost to the Government.

1.8 QUALITY CONTROL

Establish and maintain quality control for operations under this section to assure compliance with contract requirements and maintain records of quality control for all materials, fabricated parts, equipment, and construction operations. In addition, establish and maintain surveillance for quality control over sub-contractors, suppliers, or manufacturers. The quality control must include a minimum of two shop inspections during manufacture and assembly of the hydraulic cylinder assemblies power units and manifolds. The quality control includes but is not to be limited to the following:

a. Materials and workmanship.

b. Manufacture and installation of the piping, hydraulic cylinder assemblies power units and manifolds, complete.

SECTION 35 05 40.14 10 Page 11

c. Cleaning and flushing.

d. Shop assembly and tests.

e. Field erection and tests.

f. Damage and defects.

Furnish a copy of these records and tests, as well as the records of corrective action taken, to the Government.

PART 2 PRODUCTS

2.1 MATERIALS AND MECHANICAL EQUIPMENT

2.1.1 General

Provide materials and mechanical equipment that conform to the requirements indicated or specified, and if not specified, furnish materials and mechanical equipment of the best commercial grade quality suited to the intended use and as approved. All electric motors (per Section 35 20 20), hydraulic pumps, hydraulic cylinders, valves and similar items and/or accessories, of the same type and size, must be the products of the same manufacturer, unless otherwise approved. Permanently display the manufacturer's name, address, and catalog number on a nameplate securely attached to each major item of equipment.

Electrical equipment and controls that are integral to the operation of the hydraulic power equipment are called and specified in Section 35 20 20, and shall be provided in conjunction with all material specified herein.

Submit data specifications and assembly drawings showing sizes, ratings, parts and material lists, overall dimensions, and mounting dimensions with the product data.

2.1.2 Standard Products

Where items are referred to hereinafter as "similar and equal to" a particular manufacturer's product, such references have been made merely as a convenient method of indicating the type of material or equipment required, with no intention of asserting superiority thereof. The standard product of any reputable manufacturer regularly engaged in the commercial production for at least 2 years prior to this solicitation of the type and quality of material or equipment referred to will not be excluded on the basis of minor differences, provided essential requirements of the specifications relative to materials, capacity, and performance are met.

Furnish performance capacities and other pertinent information concerning the manufacturer's "equal to" standard products intended for incorporation in the work. "Equal to" standard products installed or used without such approval are at the risk of subsequent rejection.

2.1.3 Hydraulic Cylinders

Provide one of the hydraulic cylinder types listed in ISO 5598, and as specified or indicated, of tie rod design, square head standard construction. The pressure rating of the cylinder must not be less than the maximum system pressure indicated. Provide evidence that each cylinder was hydrostatically tested by the manufacturer to 200 percent of the severest

SECTION 35 05 40.14 10 Page 12 service rating and that dynamic seals are suitable for both frequent and infrequent operation and are capable of not less than 500,000 cycles of operation in systems properly maintained. The bore, stroke, rod diameter, and mounting style of the cylinder must be as indicated. Provide the hydraulic cylinder with adjustable cushions on both ends. Provide the cylinder with SAE straight thread O-ring or SAE 4 bolt hydraulic flange piping ports where indicated.

2.1.3.1 Cylinder Tubes

Machine the cylinder tube from ASTM A519, Grade 1018, heavy wall seamless steel tubing and hone the bore to a surface finish compatible with the seals being used so as to result in zero leakage past the seals.

2.1.3.2 Cylinder Heads and Caps

Fabricate the cylinder head and cap from ASTM A576, Grade 1018, steel bar stock ASTM A516/A516M, Grade 60 plate and machine finish on all surfaces.

Equip the cylinder head with a rod seal and external dirt wiper and a rod bushing piloted into the head to ensure concentricity. Rod bushings must be removable without the use of special tools and without removing the tie rods or cylinder head. Attach the cylinder tube to the head and cap by tie rods having a minimum yield strength of 100,000 psi. Removable attachments must have the cylinder tube end seals arranged to seal with pressure and be designed to prevent shearing and extrusion and to provide axial metal backup.

2.1.3.3 Pistons

Precision fit the piston to the cylinder body bore. The piston must be designed and equipped with zero leakage cup-type seals. The design must protect the piston rings from blow-out and oversqueezing. Use self-regulation cup-type seals that automatically compensate for wear.

2.1.3.4 Piston Rods (Standard Design)

Make of 90,000 to 110,000 psi high tensile strength steel using ASTM A108, Type C 1045, for rods 5/8 to 2 1/2 inches in diameter, and ASTM A108, Type CR 4140, for rods 3 to 10 inches in diameter. The rod must be case hardened to 50-54 Rockwell C, polished to a 10 microinch RMS surface finish or better, and nickel and hard-chrome plated to 0.003 inch minimum thickness.

2.1.3.5 Rod Wiper/Scraper

Provide a spring reinforced brass scraper ring which will withstand the impact and the abrasion of materials adhering to the piston rod. Split and retain the scrapers with split, bolted retainer to facilitate replacement without removal of the rod end clevis.

2.1.3.6 Piston Rod Seals

Provide low leakage V-ring, nonadjustable gland type piston and piston rod seals, designed for 3000 psi service.

2.1.3.7 Rod Seal Gland and Locking Device Flange

Fabricate the rod seal gland and locking device flange from bronze conforming to ASTM B505/B505M, Alloy No. C95400 or C93200. The ice

SECTION 35 05 40.14 10 Page 13 scraper, attached to the gland, must conform to ASTM B584, Alloy No. C86300.

2.1.3.8 Rod Locking Device

The eccentric cylinder shall be fitted with a cylinder retracted locking device. When fully retracted, the release of pressure from the locking port shall lock the rod in its fully retracted state. Locking device shall have a position switch to verify its locked status.

The main operating cylinder shall be fitted with a rod clamp locking device. This device shall lock the rod whenever pressure is removed from the locking port. Locking device shall have a pressure transducer to verify its locked status.

2.1.3.9 Cylinder Instrumentation

The eccentric cylinders are to be fitted with proximity switches to indicate fully extended and retracted position.

The main operating cylinders are to be fitted with proximity switches to indicate fully extended and retracted position. Additionally, these cylinders shall be fitted with magnetostrictiverod-style position sensors.

Sensor to be suitable for wet location with integral cable.

Provide proximity switches for sensing fully extended/retracted position.

Switch shall be supplied with factory connecting cable with IP67 protection.

All cylinder instrumentation shall be wired to a waterproof junction box mounted on the cylinder.

2.1.4 Hydraulic Power Unit

Provide a self-contained hydraulic power unit, packaged unit designed by the Contractor to operate the hydraulic cylinders in accordance with the criteria stated in paragraph DESIGN PARAMETERS. Design the power unit to meet the space limitations shown and configure essentially as indicated.

The structure of the unit both internally and externally must be adequate for the unit to be free standing and capable of being lifted or moved without structural damage. Securely attach all components including piping, motors, pumps and manifolds to the power unit in a manner to be free of damaging vibration during operation. Design and provide each unit with forklift tubes and lifting eyes to facilitate lifting or moving the unit, including the reservoir when full of oil. The HPU size is limited to the size which can fit into the dam access elevator.

2.1.5 Oil Reservoirs

Size the oil reservoir as indicated. Make the reservoir of steel with welded joints and conform to the requirements as shown. The reservoirs must conform to the requirements of ISO 4413. Provide a bolt-on mounting base along the side of the reservoir which supports the motor-driven hydraulic pumps, associated valves and accessories for design loads and speeds. The bottom of the reservoir must have a minimum clearance from the floor of not less than 12 inches. Shape and slope the reservoir bottom to facilitate emptying and cleaning. A foot valve or check suction lines must provide flooded inlets to the pumps. Provide each side of the reservoir with a cleanout opening of not less than 400 square inches clearance with a bolted, gasketed cover. Provide each reservoir with a drain with shut-off valve; a magnetic trap; low oil float level switches; and other

SECTION 35 05 40.14 10 Page 14 appurtenances as indicated and as specified herein. Equip the reservoir with a fluid level indicator and filler with built-in strainer. Provide a baffle between the intake and return lines to facilitate the separation of air and foreign matter from the hydraulic fluid. The connection between the two chambers of the reservoir must be high enough from the bottom to form a settling chamber. Bring both the intake and return pipes down to a distance of 1-1/2 pipe diameters above the tank bottom. Clean interior surfaces of the reservoir down to bright metal and coated with an epoxy-based urethane finish or an approved alternate that is compatible with oil and water. Finish the welded joints of the reservoir smooth and free from irregularities. Do not grind welds to an extent that weakens the reservoir. Until final installation of the hydraulic equipment, seal all openings with plastic closures. The capacity of each reservoir must not be less than 200 gallons. Anchor the reservoirs to the concrete by suitable anchor bolts. Furnish all piping, fittings, hose, manifold blocks, fasteners and appurtenances required to connect equipment to the reservoir.

Reservoir shall be fitted with secondary containment or constructed with double walls to prevent any release of oil due to a leak.

2.1.5.1 Reservoir Heater

Provide the reservoir with one or more screw plug type immersion heaters with a watt density not to exceed 11 watts per square inch and a built-in thermostat set to maintain the hydraulic oil at 40 degrees F. Fabricate the heater sheath and screwplug from stainless steel. Supply the heater with a watertight, stainless steel, NEMA 4X terminal housing as a minimum.

Provide a weatherproof junction box with a single phase, 120 volt, thermostat and high temperature circuit. Install the heater in a location on the reservoir vessel to maintain complete submergence of the heating element during all operating level fluctuations within the reservoir.

2.1.5.1.1 Heater Switch

Provide a thermostat to sense the oil temperature in the tank and close its contacts when the temperature drops below 50 degrees F as indicated. The thermostat must be of the bulb and capillary type and provided with a protective well which extends into the tank. The temperature adjustment range must be 50 degrees to 100 degrees F with +/- 2 degree F differential switch. Fit the switch with an external calibrated adjustment knob. The thermostat must be rated for 15 amperes at 120 volts. Provide weatherproof junction box.

2.1.5.1.2 High Temperature Switch

Provide a thermostat to sense the oil temperature in the tank and close its contacts when the temperature exceeds 150 degrees F. The thermostat must be of the bulb and capillary type and provided with a protective well which extends into the tank. The temperature adjustment range must be 50 to 300 degrees F with +/- 2 degree F differential switch. Fit the switch with an external calibrated adjustment knob. The thermostat must be rated for 15 amperes at 120 volts. Provide weatherproof junction box.

2.1.5.2 Magnetic Separators

Provide the manufacturer's standard magnetic separator in the reservoir.

The magnetic separator consists of a high-strength permanent magnet arranged for rigid mounting with the poles of the magnet exposed to the fluid in the reservoir. The magnet must be mounted on a removable rod

SECTION 35 05 40.14 10 Page 15 assembly installed through the top of the reservoir.

2.1.5.3 Low Level Float Switches

Provide each power unit with two float switches. The switches must be flanged and installed inside a 5-inch nominal diameter pipe to eliminate surge effects. The thermostat mercury type switches must have a narrow differential and be rated for 13 amperes at 120 volts. Set switches to close when oil level rises above or drops below those recommended by the manufacturer and observed during operational tests. Provide a NEMA 4X junction box.

2.1.5.4 Flexible Reservoir Breathers

Provide each hydraulic power unit with flexible reservoir breather units to eliminate the introduction of outside air into the reservoir during normal operation of the system. The breather units must be of sufficient capacity to accommodate the differential volume of the reservoir. The flexible reservoir breathers must have a bladder compatible with the system hydraulic fluid. Equip the reservoir breathers with pressure vacuum breakers. The shell must be free standing and of rugged steel construction. Construct and mount the breather in a manner to facilitate bladder replacement. Provide piping to the breather with adequate pipe unions and screwed fittings to facilitate repair or replacement of the vent bladder. Install, securely attach and support the units as shown on the hydraulic power unit.

2.1.5.5 Oil Level Gage

Provide an oil level gage with an indicating length of not less than 12 inches on each unit and position to give a visual indication of the oil level in the tank including the "low level", "add oil", "nor. min. level", and "max. level" marks. After the system is operational and all tests complete, permanently mark the levels on the tank in a manner approved by the Contracting Officer.

2.1.6 Pumps

Provide two submersible, electric motor-driven, fixed displacement, close coupled, axial piston type pumps for the hydraulic system, each rated to deliver a nominal 24 gpm at 2000 psi while operating with the specified oil in the specified temperature range, Parker hydraulic pump Series F11 or approved equal. Pumps must also be capable of delivering flow, 5 gpm minimum, at 2000 psi. Maximum rotating speed must be 1800 rpm. Safety guard exposed rotating parts. Mount the pumps in the reservoir in a manner similar to that indicated so that the pump suction is flooded. Operate the pumps on 460 volts, 60 Hz, three phase power. The pumps must be rated for continuous operation at a discharge pressure equal to or greater than the system design pressure. The rated discharge capacity of each pump must not be less than indicated when the pump is operated at the design input speed and discharge pressure.

2.1.7 Accumulators

The accumulators shall be piston type suitable for charging with nitrogen.

Provide the number of accumulators with the fluid capacity indicated.

Design the accumulators in accordance with ASME BPVC SEC VIII D1 for a rated working pressure of not less than 3000 psi. Equip accumulators with a safety device to release excessive pressure before the burst pressure is

SECTION 35 05 40.14 10 Page 16 reached. Arrange accumulators so that pressures can be checked and pistons can be easily changed without the removal of other components. Provide a ball type shutoff valve for each accumulator. Provide nitrogen gas bottles for charging of accumulators.

2.1.8 Filters

Locate the filters in the return line to the reservoir. Provide the duplex type with a differential pressure device to indicate the need for filter element service. Provide with the filter housing and cover of steel or cast iron construction. Bolt the cover to the main housing. Locate filters so that they can be changed without removal of hydraulic system components. Shutoff valves must be easily accessible. Equip the filter with a relief valve which protects the filter against excessive pressures.

Equip the filter unit with a gage or gages indicating the pressure loss or a cartridge replacement indicator. Equip the filter unit with a pressure switch to signal excessive pressure loss across the filter. The filter cartridges must not remove additives from the hydraulic fluid. The filter element must have a rating of 10 microns absolute unless a smaller mesh is recommended by the manufacturer of the component with the highest cleanliness requirement. Determine the pressure and flow rating of the filters to be compatible with his design of the power units.

2.1.9 Gauges

2.1.9.1 Pressure Gauges

Conform to ASME B40.100, have a black enameled metal case, a 4-1/2 inch dial, and a stainless steel Bourdon tube. The scale range of the gauge must be approximately 150 percent of the maximum pressure of the line in which installed. Provide safety type gauges with solid fronts and blowout backs. Provide each gauge with a pressure snubber. Panel mount the pressure gauges and make them readable from the front of the power unit after opening the doors of the enclosure. Bottom tap gauges and gauge lines in horizontal pressure lines.

2.1.9.2 Thermometer

Provide a direct indicating thermometer to indicate fluid temperature in the reservoir. Do not use Mercury in thermometers. The thermometer must have a minimum 3 inch dial with black markings on a white background, with scale range of 20 to 240 degrees F. Provide a corrosion resistant case and stem, and stainless steel wetted components. Provide thermometer wells of the separable socket type for each thermometer with a direct type bulb.

2.1.10 Manifolds

Provide pre-drilled manifold blocks for connection of control valve assemblies. Construct each manifold block of ductile iron, ASTM A536 or equal. Machine ports and passages smooth and free of burrs and sharp edges. Arrange manifold block interconnecting passages and valving so as to provide the system connections and functions as indicated. Manifold block interconnecting passages and valving must be of ample proportions to minimize internal pressure losses. Machine surfaces and recesses where valving and other components are installed to the specifications of the applicable valve or component manufacturer. Make provisions for attaching the hydraulic piping to the manifolds by the use of flanges as specified in paragraph PIPE FITTINGS and as indicated. The manifold must be in accordance with the valve manufacturers' recommendations to provide for

SECTION 35 05 40.14 10 Page 17 installation of valves, flanges and accessories. Make hydraulic interconnections between the manifold and piping with 4 bolt flanges.

Design the manifold for a minimum pressure rating of not less than 3000 psi at 150 deg F except as hereafter specified.

2.1.11 Valves

Valves must have a minimum pressure rating of 3000 psi unless stated otherwise. Where possible, manifold mount valves. Manifold mounted valves must be either cartridge type or subplate mounted. Non manifold mounted valves 1 inch or larger must have socket-welded piping connections.

Provide valves less than 1 inch with SAE straight thread ends and Buna N O-rings with tube fittings. Valves must be specifically designed and rated for hydraulic system applications.

2.1.11.1 Shut-Off Valves

Provide in-line mounted, stainless steel, lever operated, lockable, ball type. Shut-off valves at piping manifolds of each cylinder at the upstream and downstream locations for the main supply and return lines must be rated for a working pressure of 3000 psi, with socket-welded ends, double acting ball type. Shut-off valves for all other lines must be ball type, match the line size, and have a maximum allowable working pressure of 3000 psi.

The valve ends must have socket-weld pipe connections and be drilled to receive SAE Code 61 flanges. Provide a removable operating lever for each valve. Valves must be specifically designed and rated for hydraulic system applications. Provide with stainless steel valve trim including handles.

The valves must have replaceable seats and be repairable without disturbing the welded connections.

2.1.11.2 Needle Valves

Make needle valves of stainless steel and design for fine flow regulation.

Use Buna N stem sealing O-rings.

2.1.11.3 Solenoid Operated Control Valves

Solenoids must be rated for continuous operation without damage or malfunction. Solenoids must operate the valves within a 10 percent fluctuation range.