24R0010_05 50 03.00 28_Amend-0006.pdf

LSR Navigation Lock Tainter Valve System Upgrades W912EF24R0010 LSRNLTAINTERVLVS Amend-0006

SECTION TABLE OF CONTENTS

DIVISION 05 - METALS

SECTION 05 50 03.00 28

MISCELLANEOUS METAL FABRICATION AND WELDING

PART 1 GENERAL

1.1 REFERENCES

1.2 SYSTEM DESCRIPTION

1.3 SUBMITTALS

1.4 QUALIFICATION OF WELDERS AND WELDING OPERATORS

1.4.1 AWS D1.1/D1.1M - Structural Steel

1.4.2 AWS D1.6/D1.6M - Stainless Steel

1.5 SHOP DRAWINGS

PART 2 PRODUCTS

2.1 MATERIALS

2.2 FABRICATION

2.2.1 Structural Fabrication

2.2.1.1 Dimensional Tolerances for Structural Work

2.2.1.2 Structural and Stainless Steel Fabrication

2.2.1.2.1 Structural Steel Fabrication

2.2.1.2.2 Stainless Steel Fabrication

2.2.2 Welding

2.2.2.1 Welding of Structural Steel

2.2.2.2 Welding of Stainless Steel

2.2.2.3 Welding of Stainless Steel to Structural Steel

2.2.3 Machine Work

2.2.3.1 Finished Surfaces

2.2.3.2 Unfinished Surfaces

2.2.3.3 Pin Holes

2.2.3.4 Shafting

2.2.4 Miscellaneous Provisions

2.2.4.1 Cleaning of Corrosion-Resisting Steel

2.2.5 Shop Assembly

2.2.5.1 Valves

2.2.5.2 Crosshead

2.2.5.3 Rod Guides

2.2.5.4 Intermediate Rods

2.2.5.5 Connecting Rod

2.3 TESTS, INSPECTIONS, AND VERIFICATIONS

2.3.1 Material Test Reports

2.3.2 Nondestructive Testing

2.3.3 Tests of Machinery and Structural Units

2.3.4 Inspection of Structural Steel Welding

2.3.4.1 Visual Examination

2.3.4.2 Nondestructive Examination

2.3.4.3 Test Coupons

2.3.4.4 Supplemental Examination

2.3.5 Inspection of Stainless Steel Welding

SECTION 05 50 03.00 28

2.3.5.1 Visual Examination

2.3.5.2 Nondestructive Examination

2.3.5.3 Test Coupons

2.3.5.4 Supplemental Examination

2.3.6 Structural Steel Welding Repairs

2.3.7 Stainless Steel Welding Repairs

PART 3 EXECUTION

3.1 INSTALLATION

3.1.1 Alignment and Setting

3.1.2 Blocking and Wedges

3.1.3 Dissimilar Metal Isolation

3.2 PROTECTION OF FINISHED WORK

3.2.1 Machined Surfaces

3.2.2 Lubrication After Assembly

3.3 CULVERT STAINLESS STEEL LINER REPAIR

3.3.1 Embedded Stainless Steel Liner Repair

3.3.2 Bullnose Stainless Steel Liner Repair

3.4 ICE HARBOR BULLNOSE MODIFICATION

3.5 VALVE MAINTENANCE STANDS

-- End of Section Table of Contents --

SECTION 05 50 03.00 28

G4EDHCMP

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SECTION 05 50 03.00 28

MISCELLANEOUS METAL FABRICATION AND WELDING

PART 1 GENERAL

This specification applies to fabrication of all metal items not covered by the FABRICATION OF HYDRAULIC STEEL STRUCTURES specification section.

These items include the bolt-on components of valve seals and rub bars, culvert liners, bullnose modification (HLD) and all mechanical components.

For material specifications refer to the drawings and other Sections of these Specifications.

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.

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 303 (2016) Code of Standard Practice for Steel Buildings and Bridges

AISC 325 (2017) Steel Construction Manual

AISC 326 (2009) Detailing for Steel Construction

AISC 360 (2016) Specification for Structural Steel Buildings

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

ANSI/ASNT CP-189 (2020) ASNT Standard for Qualification and Certification of Nondestructive Testing Personnel

AMERICAN WELDING SOCIETY (AWS)

AWS A2.4 (2012) Standard Symbols for Welding, Brazing and Nondestructive Examination

AWS A3.0M/A3.0 (2020) Standard Welding Terms and Definitions

AWS D1.1/D1.1M (2020; Errata 1 2021) Structural Welding Code - Steel

AWS D1.2/D1.2M (2014; Errata 1 2014; Errata 2 2020) Structural Welding Code - Aluminum

AWS D1.6/D1.6M (2017) Structural Welding Code - Stainless Steel

AWS QC1 (2016) Specification for AWS Certification of Welding Inspectors

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B4.1 (1967; R 2004) Preferred Limits and Fits for Cylindrical Parts

ASME B46.1 (2020) Surface Texture, Surface Roughness, Waviness and Lay

ASTM INTERNATIONAL (ASTM)

ASTM A240/A240M (2023) Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications

ASTM A264-44T (1944T) Standard Specification for Stainless Chromium-Nickel Steel-Clad Plate

- Replaced by ASTM A264

ASTM A 380 (2006) Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment, and Systems

ASTM E 165 (2002) Standard Test Method for Liquid Penetrant Examination

ASTM E 709 (2001) Standard Guide for Magnetic Particle Examination

1.2 SYSTEM DESCRIPTION

Provide a detailed Work Plan for fabrication, including descriptions of shop facilities, equipment, number of personnel, and related information prior to the Pre-fabrication Conference, and procedures for safe conduct of the work, careful removal and disposition of materials, protection of property that is to remain undisturbed, and coordination with other work in progress. Include in the procedures a detailed description of the methods and equipment to be used for each operation, and the sequence of operations. The Work Plan shall include the recommended measuring system for ensuring dimensional tolerances. The fabrication of the following listed structures under this contract shall be performed according to this section of the specifications:

1. All fabrication not specifically covered by other specification sections

a. Material with welds will not be accepted unless the welding is specified or indicated on the drawings or otherwise approved. Welding shall not be started until welding procedures, inspectors, nondestructive testing personnel, welders, welding operators, and tackers have been qualified and approved. Each Contractor performing welding shall maintain records of the test results obtained in welding procedure, and welder, welding operator, and tacker performance qualifications.

b. The AWS D1.1/D1.1M definition of "The Engineer" as specified in the Terms and Definitions Clause of AWS D1.1/D1.1M shall refer to the Contracting Officer (KO) or Contracting Officer Representative (COR).

c. The AWS D1.6/D1.6M definition of "The Engineer" as specified in the Terms and Definitions Clause of AWS D1.6/D1.6M shall refer to the Contracting Officer (KO) or Contracting Officer Representative (COR).

d. Schedule a Prefabrication Conference as soon as possible after Notice to Proceed and prior to any fabrication. The Prefabrication Conference shall include, at a minimum, the Prime Contractor, Fabricator, the Fabricator's primary QC representative, the COR, the GQAR, and the District design engineer for the structure or structures being fabricated. The Prefabrication Conference shall occur either at the Fabrication Facilities or a similar location as deemed appropriate. The format of the prefabrication conference should include a review of these specifications, discussion of the fabricator's QCP, identification of roles and responsibilities including roles and responsibilities of fabrication subcontractors.

Submit key welding submittals, including shop drawings, welding procedure specifications, the fracture control plan, and certified testing personnel prior to holding the Prefabrication Conference. The contractor should prepare for this meeting by reviewing plans and specifications and code concerns prior to this meeting and be prepared to discuss any issues regarding the fabrication including WPS qualification requirements and required witnessing of testing.

Identify and discuss complicated connections that require prototyping for both welding and inspection. In addition, hold points/witness points will be established during the prefabrication conference.

1.3 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. The following shall be submitted in accordance with SECTION 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Welding Of Structural Steel-HLD ; G, ST

Welding Of Structural Steel-LMA ; G, ST

Welding Of Structural Steel-LGA ; G, ST

Welding Of Structural Steel-LLA ; G, ST

Welding Of Stainless Steel-HLD ; G, ST ME

Welding Of Stainless Steel-LMA ; G, ST ME

Welding Of Stainless Steel-LGA ; G, ST ME

Welding Of Stainless Steel-LLA ; G, ST ME

Structural Steel Welding Repairs - HLD ; G, ST

Structural Steel Welding Repairs - LMA ; G, ST

Structural Steel Welding Repairs - LGA ; G, ST

Structural Steel Welding Repairs - LLA ; G, ST

Stainless Steel Welding Repairs - HLD ; G, ST

Stainless Steel Welding Repairs - LMA ; G, ST

Stainless Steel Welding Repairs - LGA ; G, ST

Stainless Steel Welding Repairs - LLA ; G, ST

Work Plan ; G, ST

SD-02 Shop Drawings

Shop Drawings-HLD ; G, ST ME

Shop Drawings-LMA ; G, ST ME

Shop Drawings-LGA ; G, ST ME

Shop Drawings-LLA ; G, ST ME

Seal Surface Repair Survey And Repair-HLD ; G, ST

Seal Surface Repair Survey And Repair-LMA ; G, ST

Seal Surface Repair Survey And Repair-LGA ; G, ST

Seal Surface Repair Survey And Repair-LLA ; G, ST

SD-06 Test Reports

Material Test Reports - HLD ; G, ST ME

Material Test Reports - LMA ; G, ST ME

Material Test Reports - LGA ; G, ST ME

Material Test Reports - LLA ; G, ST ME

Certified test reports for materials with all materials delivered to the site.

SD-07 Certificates

Qualification Of Welders And Welding Operators - HLD ; G, ST

Qualification Of Welders And Welding Operators - LMA ; G, ST

Qualification Of Welders And Welding Operators - LGA ; G, ST

Qualification Of Welders And Welding Operators - LLA ; G, ST

Certified Welding Inspector - HLD ; G, ST

Certified Welding Inspector - LMA ; G, ST

Certified Welding Inspector - LGA ; G, ST

Certified Welding Inspector - LLA ; G, ST

1.4 QUALIFICATION OF WELDERS AND WELDING OPERATORS

QUALIFICATION OF WELDERS AND WELDING OPERATORS - HLD

QUALIFICATION OF WELDERS AND WELDING OPERATORS - LMA

QUALIFICATION OF WELDERS AND WELDING OPERATORS - LGA

QUALIFICATION OF WELDERS AND WELDING OPERATORS - LLA

1.4.1 AWS D1.1/D1.1M - Structural Steel

Submit welder, welding operator and tacker qualification certification for each welder, welding operator or tack welder to the Government Representative/Contracting Officer/Engineer and approved before fabrication is commenced in accordance with paragraph Welded Connections.

A CWI meeting the specified qualifications shall approve all welder qualifications. Welders, welding operators, and tack welders shall be limited to welding procedures for which they are certified. Test welds shall be prepared, welded, and tested in accordance with the requirements of AWS D1.1/D1.1M . Before assigning any welder, welding operator, or tacker to work under this contract, submit the names of the welders, welding operators, and tackers to be employed, and certification that each individual is qualified as specified. The certification shall state the type of welding and positions for which the welder, welding operator, or tacker is qualified, the code and procedure under which the individual is qualified, the date qualified, and the name of the firm and person certifying the qualification tests. The certification shall be kept current for the duration of the contract. Welder and welding operator qualification test records shall be submitted on forms similar or equivalent to the sample forms in AWS D1.1/D1.1M . All qualifications shall be current prior to commencing any work. Submit a log for each welder showing that he/she is current in the process and procedures being proposed for this work.

1.4.2 AWS D1.6/D1.6M - Stainless Steel

Submit welder, welding operator and tacker qualification certification for each welder, welding operator or tack welder to the Government Representative/Contracting Officer/ Engineer and approved before fabrication is commenced in accordance with paragraph Welded Connections.

A CWI meeting the specified qualifications shall approve all welder qualifications. Welders, welding operators, and tack welders shall be limited to welding procedures for which they are certified. Test welds shall be prepared, welded, and tested in accordance with the requirements of AWS D1.6/D1.6M . Before assigning any welder, welding operator, or tacker to work under this contract, submit the names of the welders, welding operators, and tackers to be employed, and certification that each individual is qualified as specified. The certification shall state the type of welding and positions for which the welder, welding operator, or tacker is qualified, the code and procedure under which the individual is qualified, the date qualified, and the name of the firm and person certifying the qualification tests. The certification shall be kept current for the duration of the contract. Welder and welding operator qualification test records shall be submitted on forms similar or equivalent to the sample forms in AWS D1.6/D1.6M . All qualifications shall be current prior to commencing any work. Submit a log for each welder showing that he/she is current in the process and procedures being proposed for this work.

1.5 SHOP DRAWINGS

Prepare all shop drawings in accordance with AWS A2.4 , AWS A3.0M/A3.0 , AISC 303 , AISC 326 , AISC 360 , and AISC 325 . Elements of fabricated items inadvertently omitted on contract drawings shall be returned to the COR for detailing or shall be detailed by the fabricator and so indicated on the shop drawings. Any and all details developed by the fabricator shall be clouded on the shop drawings for separate approval by the COR. Any items designed by the Contractor shall be prepared and sealed by a Registered Professional Engineer. No splices shall be included in the structure without approval of the COR. All field welds required shall be identified on the shop drawings. Each weld, both shop and field welds, required shall be provided a unique identifier to permit tracking on the weld tracking log and shall include nondestructive examination symbols in accordance with the Nondestructive Examination Symbols Clause of AWS A2.4 .

Prior to performing any fabrication, submit complete, detailed shop drawings to the Contracting Officer for approval. Shop drawings shall show complete details of materials, tolerances, connections, and proposed welding sequences. Shop drawings shall include catalog cuts, templates, fabrication and assembly details, and type, grade, and class of materials, as appropriate. Utilize AWS A2.4 , AWS A3.0M/A3.0 , AISC 303 , AISC 325 , and AISC 326 for shop drawing preparation. Each member shall be identified following the numbering scheme shown on the drawings. A table shall be provided containing a list of all members and a reference to each material certificate and test report that applies to that member. Shop drawings shall identify weld procedures and nondestructive examination required for each weld. Any and all splices shall be included in the shop drawings and clouded for COR approval.

SHOP DRAWINGS-HLD

SHOP DRAWINGS-LMA

SHOP DRAWINGS-LGA

SHOP DRAWINGS-LLA

PART 2 PRODUCTS

2.1 MATERIALS

Materials used for fabrication must conform to the requirements shown on the drawings and as specified in all other Sections of these Specifications.

2.2 FABRICATION

2.2.1 Structural Fabrication

Material must be straight before being laid off or worked. If straightening is necessary it shall be done by methods that will not impair the metal. Sharp kinks or bends shall be cause for rejection of the material. Material with welds will not be accepted except where welding is definitely specified, indicated or otherwise approved. Bends shall be made by approved dies, press brakes or bending rolls. Where heating is required, precautions shall be taken to avoid overheating the metal and it shall be allowed to cool in a manner that will not impair the original properties of the metal. Proposed flame cutting of material other than structural steel shall be subject to approval and shall be indicated on detail drawings. Shearing shall be accurate and all portions of the work shall be neatly finished. Corners shall be square and true unless otherwise shown. Re-entrant cuts shall be filleted to a minimum radius of 3/4 inch unless otherwise approved. Finished members shall be free of twists, bends and open joints. Bolts, nuts and screws shall be tight.

2.2.1.1 Dimensional Tolerances for Structural Work

Welded assemblies must meet the tolerances required in the Fabrication Clause of AWS D1.1/D1.1M , except as otherwise specified in the Contract drawings and specifications. Dimensions must be measured by an approved calibrated steel tape of approximately the same temperature as the material being measured. At a minimum structural members shall not deviate from the dimensions shown by more than 1/16 inch for members 30 feet or less in length and by more than 1/8 inch for members over 30 feet in length.

2.2.1.2 Structural and Stainless Steel Fabrication

2.2.1.2.1 Structural Steel Fabrication

Structural steel may be cut by mechanically guided or hand-guided torches, provided an accurate profile with a surface that is smooth and free from cracks and notches is obtained. Surfaces and edges to be welded shall be prepared in accordance with the Fabrication Clause of AWS D1.1/D1.1M .

Where structural steel is not to be welded, chipping or grinding will not be required except as necessary to remove slag and sharp edges of mechanically guided or hand-guided cuts not exposed to view. Hand-guided cuts which are to be exposed or visible shall be chipped, ground or machined to sound metal.

2.2.1.2.2 Stainless Steel Fabrication

Stainless steel may be cut by mechanically guided or hand-guided torches, provided an accurate profile with a surface that is smooth and free from cracks and notches is obtained. Surfaces and edges to be welded shall be prepared in accordance with the Fabrication Clause of AWS D1.6/D1.6M .

Where stainless steel is not to be welded, chipping or grinding will not be required except as necessary to remove slag and sharp edges of mechanically guided or hand-guided cuts not exposed to view. Hand-guided cuts which are to be exposed or visible shall be chipped, ground or machined to sound metal.

2.2.2 Welding

2.2.2.1 Welding of Structural Steel

a. Welding Procedures for Structural Steel - Welding procedures for structural steel shall be prequalified as described in the Prequalification of WPSs Clause of AWS D1.1/D1.1M , or shall be qualified by tests as prescribed in AWS D1.1/D1.1M , Qualification Clause. Properly documented evidence of compliance with all requirements of these specifications for previous qualification tests shall establish a welding procedure as prequalified. For welding procedures qualified by tests, the test welding and specimen testing must be witnessed and the test report document signed by the Contracting Officer. Approval of any welding procedure will not relieve the Contractor of the responsibility for producing a finished structure meeting all requirements of these specifications. The Contractor will be directed or authorized to make any changes in previously approved welding procedures that are deemed necessary or desirable by the Contractor Officer. The Contractor shall submit a complete schedule of welding procedures for each steel structure to be welded. The schedule shall conform to the requirements specified in the provisions AWS D1.1/D1.1M . The schedule shall provide detailed procedure specifications and tables or diagrams showing the procedures to be used for each required joint. Welding procedures must include filler metal, preheat, interpass temperature and stress-relief heat treatment requirements. Each welding procedure shall be clearly identified as being prequalified or required to be qualified by tests. Welding procedures must show types and locations of welds designated or in the specifications to receive nondestructive examination.

b. Welding Process - Welding of structural steel shall be by an electric arc welding process using a method which excludes the atmosphere from the molten metal and shall conform to the applicable provisions of AWS D1.1/D1.1M . Welding shall be such as to minimize residual stresses, distortion and shrinkage.

c. Structural Steel Welding Repair-

Welding of Structural Steel-HLD Welding of Structural Steel-LMA Welding of Structural Steel-LGA Welding of Structural Steel-LLA

c. Welding Technique

(1) Filler Metal - The electrode, electrode-flux combination and grade of weld metal shall conform to the appropriate AWS specification for the base metal and welding process being used or shall be as shown where a specific choice of AWS specification allowables is required. The AWS designation of the electrodes to be used shall be included in the schedule of welding procedures.

Only low hydrogen electrodes shall be used for manual shielded metal-arc welding regardless of the thickness of the steel. A controlled temperature storage oven shall be used at the job site as prescribed by AWS D1.1/D1.1M to maintain low moisture of low hydrogen electrodes.

(2) Preheat and Interpass Temperature - Preheating shall be performed as required by AWS D1.1/D1.1M , or as otherwise specified except that the temperature of the base metal shall be at least 70 degrees F. The weldments to be preheated shall be slowly and uniformly heated by approved means to the prescribed temperature, held at that temperature until the welding is completed and then permitted to cool slowly in still air.

(3) Stress-Relief Heat Treatment - Where stress relief heat treatment is specified or shown, it shall be in accordance with the requirements of AWS D1.1/D1.1M unless otherwise authorized or directed.

d. Workmanship - Workmanship for welding shall be in accordance with AWS D1.1/D1.1M , Fabrication Clause and other applicable requirements of these specifications.

(1) Preparation of Base Metal - Prior to welding the Contractor shall inspect surfaces to be welded to assure compliance with

AWS D1.1/D1.1M .

(2) Temporary Welds - Temporary welds required for fabrication and erection shall be made under the controlled conditions prescribed for permanent work. Temporary welds shall be made using low-hydrogen welding electrodes and by welders qualified for permanent work as specified in these specifications. Preheating for temporary welds shall be as required by AWS D1.1/D1.1M for permanent welds except that the minimum temperature shall be 120 degrees F in any case. In making temporary welds arcs shall not be struck in other than weld locations. Each temporary weld shall be removed and ground flush with adjacent surfaces after serving its purpose.

(3) Tack Welds - Tacks welds that are to be incorporated into the permanent work shall be subject to the same quality requirements as the permanent welds and shall be cleaned and thoroughly fused with permanent welds. Preheating shall be performed as specified above for temporary welds. Multiple-pass tack welds shall have cascaded ends. Defective tack welds shall be removed before permanent welding.

e. Structural and Stainless Steel Welding Repairs - - Prior to making repairs submit a plan for the repairs. See subparts titled "Structural Steel Welding Repairs" and "Stainless Steel Welding Repairs" for reference.

2.2.2.2 Welding of Stainless Steel

a. Welding Procedures for Stainless Steel - Welding procedures for stainless steel shall be prequalified as described in the Prequalification Clause of AWS D1.6/D1.6M , or shall be qualified by tests as prescribed in AWS D1.6/D1.6M , Qualification Clause. Properly documented evidence of compliance with all requirements of these specifications for previous qualification tests shall establish a welding procedure as prequalified. For welding procedures qualified by tests, the test welding and specimen testing must be witnessed and the test report document signed by the Contracting Officer. Approval of any welding procedure will not relieve the Contractor of the responsibility for producing a finished structure meeting all requirements of these specifications. The Contractor will be directed or authorized to make any changes in previously approved welding procedures that are deemed necessary or desirable by the Contractor Officer. The Contractor shall submit a complete schedule of welding procedures for each steel structure to be welded. The schedule shall conform to the requirements specified in the provisions AWS D1.6/D1.6M .

The schedule shall provide detailed procedure specifications and tables or diagrams showing the procedures to be used for each required joint. Welding procedures must include filler metal, preheat, interpass temperature and stress-relief heat treatment requirements.

Each welding procedure shall be clearly identified as being prequalified or required to be qualified by tests. Welding procedures must show types and locations of welds designated or in the specifications to receive nondestructive examination. All stainless steel to be welded shall possess low carbon content.

Welding of Stainless Steel-HLD Welding of Stainless Steel-LMA Welding of Stainless Steel-LGA

Welding of Stainless Steel-LLA

b. Welding Process - Welding of stainless steel shall be by an electric arc welding process using a method which excludes the atmosphere from the molten metal and shall conform to the applicable provisions of AWS D1.6/D1.6M . Welding shall be such as to minimize residual stresses, distortion and shrinkage.

c. Welding Technique

(1) Filler Metal - The electrode, electrode-flux combination and grade of weld metal shall conform to the appropriate AWS specification for the base metal and welding process being used or shall be as shown where a specific choice of AWS specification allowables is required. The AWS designation of the electrodes to be used shall be included in the schedule of welding procedures.

Only low hydrogen electrodes shall be used for manual shielded metal-arc welding regardless of the thickness of the steel. A controlled temperature storage oven shall be used at the job site as prescribed by AWS D1.6/D1.6M to maintain low moisture of low hydrogen electrodes.

(2) Preheat and Interpass Temperature - Preheating shall be performed as required by AWS D1.6/D1.6M or as otherwise specified. The weldments to be preheated shall be slowly and uniformly heated by approved means to the prescribed temperature, held at that temperature until the welding is completed and then permitted to cool slowly in still air.

(3) Stress-Relief Heat Treatment - Where stress relief heat treatment is specified or shown, it shall be in accordance with the requirements of AWS D1.6/D1.6M unless otherwise authorized or directed.

d. Stainless Steel Welding Repairs - Prior to making repairs submit a plan for the repairs.

e. Workmanship - Workmanship for welding shall be in accordance with AWS D1.6/D1.6M , and other applicable requirements of these specifications.

(1) Preparation of Base Metal - Prior to welding the Contractor shall inspect surfaces to be welded to assure compliance with

AWS D1.6/D1.6M .

(2) Temporary Welds - Temporary welds required for fabrication and erection shall be made under the controlled conditions prescribed for permanent work. Temporary welds shall be made using low-hydrogen welding electrodes and by welders qualified for permanent work as specified in these specifications. Preheating for temporary welds shall be as required by AWS D1.6/D1.6M for permanent welds except that the minimum temperature shall be 120 degrees F in any case. In making temporary welds arcs shall not be struck in other than weld locations. Each temporary weld shall be removed and ground flush with adjacent surfaces after serving its purpose.

(3) Tack Welds - Tacks welds that are to be incorporated into the permanent work shall be subject to the same quality requirements as the permanent welds and shall be cleaned and thoroughly fused with permanent welds. Preheating shall be performed as specified above for temporary welds. Multiple-pass tack welds shall have cascaded ends. Defective tack welds shall be removed before permanent welding.

2.2.2.3 Welding of Stainless Steel to Structural Steel

Where stainless steel is welded directly to structural steel, such as the seal mounting plate at the bottom of the skin plate, the requirements of AWS D1.6/D1.6M shall apply.

2.2.3 Machine Work

Tolerances, allowances and gauges for metal fits between plain, non-threaded, cylindrical parts shall conform to ASME B4.1 for the class of fit shown or required unless otherwise shown on approved detail drawings. Where fits are not shown they shall be suitable as approved.

Tolerances for machine-finished surfaces designated by non-decimal dimensions shall be within 1/64 inch. Sufficient machining stock shall be allowed on placing pads to ensure true surfaces of solid material.

Finished contact or bearing surfaces shall be true and exact to secure full contact. Journal surfaces shall be polished and all surfaces shall be finished with sufficient smoothness and accuracy to ensure proper operation when assembled. Parts entering any machine shall be accurately machined and all like parts shall be interchangeable except that parts assembled together for drilling or reaming of holes or machining will not be required to be interchangeable with like parts. All drilled holes for bolts shall be accurately located.

2.2.3.1 Finished Surfaces

Surface finishes indicated or specified shall be in accordance with ASME B46.1 . Values of required roughness heights are arithmetical average deviations expressed in microinches. These values are maximum. Lesser degrees will be satisfactory unless otherwise indicated. Compliance with surface requirements shall be determined by sense of feel and visual inspection of the work compared to Roughness Comparison Specimens in accordance with the provisions of ASME B46.1 . Values of roughness width and waviness height shall be consistent with the general type of finish specified by roughness height. Where the finish is not indicated or specified it shall be that which is most suitable for the particular surface, provide the class of fit required and be indicated on the detail drawings by a symbol which conforms to ASME B46.1 when machine finishing is provided. Flaws such as scratches, ridges, holes, peaks, cracks or checks which will make the part unsuitable for the intended use will be cause for rejection.

2.2.3.2 Unfinished Surfaces

All work shall be laid out to secure proper matching of adjoining unfinished surfaces unless otherwise directed. Where there is a large discrepancy between adjoining unfinished surfaces they shall be chipped and ground smooth or machined to secure proper alignment. Unfinished surfaces shall be true to the lines and dimensions shown and shall be chipped or ground free of all projections and rough spots. Depressions or holes not affecting the strength or usefulness of the parts shall be filled in an approved manner.

2.2.3.3 Pin Holes

Pin holes shall be bored true to gauges, smooth, straight and at right angles to the axis of the member. The boring shall be done after the member is securely fastened in position.

2.2.3.4 Shafting

All shafting shall be turned or ground hot-rolled or cold-rolled steel as required unless otherwise specified or authorized. Fillets shall be provided where changes in section occur. Cold-finished shafting may be used where keyseating is the only machine work required.

2.2.4 Miscellaneous Provisions

2.2.4.1 Cleaning of Corrosion-Resisting Steel

Oil, paint and other foreign substances shall be removed from corrosion-resisting steel surfaces after fabrication. Cleaning shall be done by vapor degreasing or by the use of cleaners of the alkaline, emulsion or solvent type. After the surfaces have been cleaned they shall be given a final rinsing with clean water followed by a 24 hour period during which the surfaces are intermittently wet with clean water and then allowed to dry for the purpose of inspecting the clean surfaces. The surfaces shall be visually inspected for evidence of paint, oil, grease, welding slag, heat treatment scale, iron rust or other forms of contamination. If evidence of foreign substance exist the surface shall be cleaned in accordance with the applicable provisions of ASTM A 380 .

The proposed method of treatment shall be furnished for approval. After treatment the surfaces shall be visually reinspected. Brushes used to remove foreign substances shall have only stainless steel or nonmetallic bristles. Any contamination occurring subsequent to the initial cleaning shall be removed by one or more of the methods indicated above.

2.2.5 Shop Assembly

Each machinery and structural unit furnished shall be assembled in the shop to determine the correctness of the fabrication and matching of the component parts unless otherwise specified. Tolerances shall not exceed those shown. Each unit assembled shall be closely checked to ensure that all necessary clearances have been provided and that binding does not occur in any moving part. Errors or defects disclosed shall be immediately remedied by the Contractor without cost to the Government.

Before disassembly for shipment each piece of a machinery or structural unit shall be match-marked to facilitate erection in the field. The location of match-marks shall be indicated by circling with a ring of white paint after the shop coat of paint has been applied or as otherwise directed. Assemblies shall be inspected in the shop by the Contracting Officers Representative.

2.2.5.1 Valves

Shop assemble each valve with seals, lifting eye bearings and trunnion bushings. Remove seals prior to shipment and installation.

2.2.5.2 Crosshead

Shop assemble crossheads with bushings, wipers and keepers, crosshead guide rods and guide rod supports.

2.2.5.3 Rod Guides

Shop assemble rod guides with bearings, wipers and keepers

2.2.5.4 Intermediate Rods

Shop assemble intermediate rods and rod connectors. Disassemble and protect threads for shipment.

2.2.5.5 Connecting Rod

Shop assemble Connecting rod with bearings and test fit connection with valve and crosshead.

2.3 TESTS, INSPECTIONS, AND VERIFICATIONS

The Contractor shall have required material tests and analyses performed and certified by an approved laboratory to demonstrate that materials are in conformity with the specifications. These tests and analyses shall be performed and certified at the Contractor's expense. Tests, inspections, and verifications shall conform to the requirements of the particular sections of these specifications for the respective items of work unless otherwise specified or authorized. Tests shall be conducted in the presence of the Contracting Officer if so required. The Contractor shall furnish specimens and samples for additional independent tests and analyses upon request by the Contracting Officer. Specimens and samples shall be properly labeled and prepared for shipment.Weld inspectors shall hold a current certification as a certified welding inspector (CWI) in accordance with AWS QC1. Copies of the weld inspector's certification and qualifications for all assistant inspectors shall be submitted. Submit the following:

Certified Welding Inspector - HLD Certified Welding Inspector - LMA Certified Welding Inspector - LGA Certified Welding Inspector - LLA

2.3.1 Material Test Reports

Certified test reports shall be submitted to the Government prior to any material being delivered to the site. Submit the following:

Material Test Reports - HLD Material Test Reports - LMA Material Test Reports - LGA Material Test Reports - LLA

2.3.2 Nondestructive Testing

When doubt exists as to the soundness of any material part such part may be subjected to any form of nondestructive testing determined by the Contracting Officer. This may include ultrasonic, magnaflux, dye penetrant, x-ray, gamma ray or any other test that will thoroughly investigate the part in question. The cost of such investigation will be borne by the Government. Any defects will be cause for rejection and rejected parts shall be replaced and retested at the Contractor's expense.

2.3.3 Tests of Machinery and Structural Units

The details for tests of machinery and structural units shall conform to the requirements of the particular sections of these specifications covering these items. After being installed at the site each complete machinery or structural unit shall be operated through a minimum of 5 complete cycles to demonstrate to the satisfaction of the Contracting Officer that it meets the specified operational requirements in all respects.

2.3.4 Inspection of Structural Steel Welding

The Contractor shall maintain an approved inspection system and perform required inspections. Welding shall be subject to inspection to determine conformance with the requirements of AWS D1.1/D1.1M , the approved welding procedures and provisions stated in other sections of these specifications. Nondestructive examination of designated welds will be required. Supplemental examination of any joint or coupon cut from any location in any joint may be required.

2.3.4.1 Visual Examination

All visual examination of completed welds shall be cleaned and carefully examined by a Certified Weld Inspector for insufficient throat or leg sizes, cracks, undercutting, overlap, excessive convexity or reinforcement and other surface defects to ensure compliance with the requirements of

AWS D1.1/D1.1M .

2.3.4.2 Nondestructive Examination

The nondestructive examination of shop and field welds shall be performed as designated or described in the sections of these specifications covering the particular items of work.

a. Testing Agency - The nondestructive examination of welds and the evaluation of examination tests as to the acceptability of the welds shall be performed by a testing agency adequately equipped and competent to perform such services or by the Contractor using suitable equipment and qualified personnel. The Contractor's weld inspector shall hold a current certification as a certified welding inspector (CWI) in accordance with AWS QC1. All personnel who perform NDT shall be qualified in accordance with: ANSI/ASNT CP-189 NDT Level II or III.Copies of the weld inspector's certification and qualifications for all assistant inspectors shall be submitted. In either case written approval of the examination procedures is required and the examination tests shall be made in the presence of the Contracting Officer. The evaluation of examination tests shall be subject to the approval and all records shall become the property of the Government.

b. Examination Procedures - Examination procedures shall conform to the following requirements.Non destructive testing shall be performed by ASNT certified inspectors according to ASNT CP-189

(1) Ultrasonic Testing - Making, evaluating and reporting ultrasonic testing of welds shall conform to the requirements of AWS D1.1/D1.1M ,. The ultrasonic equipment shall be capable of making a permanent record of the test indications. A record shall be made of each weld tested.

(2) Radiographic Testing - Making, evaluating and reporting radiographic testing of welds shall conform to the requirements of

AWS D1.1/D1.1M ,.

(3) Magnetic Particle Inspection - Magnetic particle inspection of welds shall conform to the applicable provisions of ASTM E 709 .

(4) Dye Penetrant Inspection - Dye penetrant inspection of welds shall conform to the applicable provisions of ASTM E 165 .

c. Acceptability of Welds - Welds shall be unacceptable if shown to have defects prohibited by AWS D1.1/D1.1M , or possess any degree of incomplete fusion, inadequate penetration or undercutting.

d. Welds to be Subject to Nondestructive Examination

(1) One hundred (100) percent of completed welds shall be cleaned and visually inspected to ensure compliance with the requirements of AWS D1.1/D1.1M .

(2) 100 percent of full penetration welds shall be ultrasonically tested or Radiographic tested. 100 percent of full penetration welds in T joints shall be ultrasonically tested.

(3) 25 percent of all fillet and partial penetration welds shall be inspected by magnetic particle testing or liquid penetrant testing.

2.3.4.3 Test Coupons

The Government reserves the right to require the Contractor to remove coupons from completed work when doubt as to soundness cannot be resolved by nondestructive examination. Should tests of any two coupons cut from the work of any welder show strengths less than that specified for the base metal it will be considered evidence of negligence or incompetence and such welder shall be removed from the work. When coupons are removed from any part of a structure the members cut shall be repaired in a neat manner with joints of the proper type to develop the full strength of the members. Repaired joints shall be peened as approved or directed to relieve residual stress. The expense for removing and testing coupons, repairing cut members and the nondestructive examination of repairs shall be borne by the Government or the Contractor in accordance with the Contract Clauses INSPECTION AND ACCEPTANCE.

2.3.4.4 Supplemental Examination

When the soundness of any weld is suspected of being deficient due to faulty welding or stresses that might occur during shipment or erection the Government reserves the right to perform nondestructive supplemental examinations before final acceptance. The cost of such inspection will be borne by the Government.

2.3.5 Inspection of Stainless Steel Welding

The Contractor shall maintain an approved inspection system and perform required inspections. Welding shall be subject to inspection to determine conformance with the requirements of AWS D1.6/D1.6M , the approved welding procedures and provisions stated in other sections of these specifications. Nondestructive examination of designated welds will be required. Supplemental examination of any joint or coupon cut from any location in any joint may be required.

2.3.5.1 Visual Examination

All visual examination of completed welds shall be cleaned and carefully examined by a Certified Weld Inspector for insufficient throat or leg sizes, cracks, undercutting, overlap, excessive convexity or reinforcement and other surface defects to ensure compliance with the requirements of AWS D1.6/D1.6M , Inspection Clause.

2.3.5.2 Nondestructive Examination

The nondestructive examination of shop and field welds shall be performed as designated or described in the sections of these specifications covering the particular items of work.

a. Testing Agency - The nondestructive examination of welds and the evaluation of examination tests as to the acceptability of the welds shall be performed by a testing agency adequately equipped and competent to perform such services or by the Contractor using suitable equipment and qualified personnel. The Contractor's weld inspector shall hold a current certification as a certified welding inspector (CWI) in accordance with AWS QC1. Copies of the weld inspector's certification and qualifications for all assistant inspectors shall be submitted. In either case written approval of the examination procedures is required and the examination tests shall be made in the presence of the Contracting Officer. The evaluation of examination tests shall be subject to the approval and all records shall become the property of the Government.

b. Examination Procedures - Examination procedures shall conform to the following requirements. Non destructive testing shall be performed by ASNT certified inspectors according to ASNT CP-189

(1) Ultrasonic Testing - Making, evaluating and reporting ultrasonic testing of welds shall conform to the requirements of AWS D1.6/D1.6M ,. The ultrasonic equipment shall be capable of making a permanent record of the test indications. A record shall be made of each weld tested.

(2) Radiographic Testing - Making, evaluating and reporting radiographic testing of welds shall conform to the requirements of

AWS D1.6/D1.6M ,.

(3) Dye Penetrant Inspection - Dye penetrant inspection of welds shall conform to the applicable provisions of ASTM E 165 .

c. Acceptability of Welds - Welds shall be unacceptable if shown to have defects prohibited by AWS D1.6/D1.6M , Inspection Clause, or possess any degree of incomplete fusion, inadequate penetration or undercutting.

d. Welds to be Subject to Nondestructive Examination

(1) One hundred (100) percent of completed welds shall be cleaned and visually inspected to ensure compliance with the requirements of AWS D1.6/D1.6M .

(2) 100 percent of full penetration welds shall be ultrasonically tested or Radiographic tested.

(3) 25 percent of all fillet and partial penetration welds shall be inspected by liquid penetrant testing.

2.3.5.3 Test Coupons

The Government reserves the right to require the Contractor to remove coupons from completed work when doubt as to soundness cannot be resolved by nondestructive examination. Should tests of any two coupons cut from the work of any welder show strengths less than that specified for the base metal it will be considered evidence of negligence or incompetence and such welder shall be removed from the work. When coupons are removed from any part of a structure the members cut shall be repaired in a neat manner with joints of the proper type to develop the full strength of the members. Repaired joints shall be peened as approved or directed to relieve residual stress. The expense for removing and testing coupons, repairing cut members and the nondestructive examination of repairs shall be borne by the Government or the Contractor in accordance with the Contract Clauses INSPECTION AND ACCEPTANCE.

2.3.5.4 Supplemental Examination

When the soundness of any weld is suspected of being deficient due to faulty welding or stresses that might occur during shipment or erection the Government reserves the right to perform nondestructive supplemental examinations before final acceptance. The cost of such inspection will be borne by the Government.

2.3.6 Structural Steel Welding Repairs

Defective welds in the structural steel welding repairs shall be repaired in accordance with AWS D1.1/D1.1M . Defective weld metal shall be removed to sound metal by use of air carbon-arc or oxygen gouging. The surfaces shall be thoroughly cleaned before welding. Welds that have been repaired shall be retested by the same methods used in the original inspection.

Except for the repair of members cut to remove test coupons and found to have acceptable welds costs of repairs and retesting shall be borne by the Contractor. Prior to performing repairs, submit the following:

Structural Steel Welding Repairs - HLD Structural Steel Welding Repairs - LMA Structural Steel Welding Repairs - LGA Structural Steel Welding Repairs - LLA

2.3.7 Stainless Steel Welding Repairs

Defective welds in the stainless steel welding repairs shall be repaired in accordance with AWS D1.6/D1.6M . Defective weld metal shall be removed to sound metal by use of air carbon-arc or oxygen gouging. The surfaces shall be thoroughly cleaned before welding. Welds that have been repaired shall be retested by the same methods used in the original inspection.

Except for the repair of members cut to remove test coupons and found to have acceptable welds costs of repairs and retesting shall be borne by the Contractor. Prior to performing repairs, submit the following:

Stainless Steel Welding Repairs - HLD Stainless Steel Welding Repairs - LMA

Stainless Steel Welding Repairs - LGA Stainless Steel Welding Repairs - LLA

PART 3 EXECUTION

3.1 INSTALLATION

All parts to be installed shall be thoroughly cleaned. Packing compounds, rust, dirt, grit and other foreign matter shall be removed. Holes and grooves for lubrication shall be cleaned. Enclosed chambers or passages shall be examined to make sure that they are free from damaging materials. Where units or items are shipped as assemblies they will be inspected prior to installation. Disassembly, cleaning and lubrication will not be required except where necessary to place the assembly in a clean and properly lubricated condition. Pipe wrenches, cold chisels or other tools likely to cause damage to the surfaces of rods, nuts or other parts shall not be used for assembling and tightening parts. Bolts and screws shall be tightened firmly and uniformly but care shall be taken not to overstress the threads. When a half nut is used for locking a full nut the half nut shall be placed first and followed by the full nut. Threads of all bolts except high strength bolts, nuts and screws shall be lubricated with an approved lubricant before assembly. Threads of corrosion-resisting steel bolts and nuts shall be coated with an approved antigalling compound. Driving and drifting bolts or keys will not be permitted.

3.1.1 Alignment and Setting

Each machinery or structural unit shall be accurately aligned by the use of steel shims or other approved methods so that no binding in any moving parts or distortion of any member occurs before it is fastened in place.

The alignment of all parts with respect to each other shall be true within the respective tolerances required. Machines shall be set true to the elevations shown.

3.1.2 Blocking and Wedges

All blocking and wedges used during installation for the support of parts to be grouted in foundations shall be removed before final grouting unless otherwise directed. Blocking and wedges left in the foundations with approval shall be of steel or iron.

3.1.3 Dissimilar Metal Isolation

Any dissimilar metals in contact with each other must be protected against galvanic or corrosive action by means of a non-conductive isolation gasket, pad or other means as approved by the Contracting Officer. Isolation washers and sleeves for bolted connections must be used to prevent contact between dissimilar metals. This requirement does not apply where dissimilar metals are welded directly to each other.

3.2 PROTECTION OF FINISHED WORK

3.2.1 Machined Surfaces

Machined surfaces shall be thoroughly cleaned of foreign matter. All finished surfaces shall be protected by suitable means. Unassembled pins and bolts shall be oiled and wrapped with moisture resistant paper or protected by other approved means.