22Q0003 Pintle Scope and Drawings Amendment 0001.pdf

PART 1 GENERAL

1.1 SCOPE

Fabrication of eight (8) pintles balls, eight (8) pintle bushings, and supply various specified items required for installation of these pieces.

The pintles must have an outer bearing surface finished truly hemispherical and the pintle bushings shall have inner bearing surfaces finished truly hemispherical. Machine work to be performed under this contract is shown on the attached drawings and is described by this specification.

Summary of Work

a. Fabricate pintles and pintle bushings as specified in drawings.

b. Machine hemispherical surfaces on pintle bushings as specified

c. Mill grooves into pintle bushings for lubricant routing and for

O-ring seals

d. Supply specified O-ring seals, keys, and fasteners

The height of the pintle ball and pintle bushing determines the miter gate elevation. Once installed, there is no method to adjust the gate elevation. For this reason, care must be taken to minimize the change in assembled height, and the machined pintle and pintle bushing height shall conform attached drawing dimensions.

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.

AEROSPACE INDUSTRIES ASSOCIATION OF AMERICA, INC. (AIA/NAS)

AIA/NAS NAS410 (2020; Rev 4) NAS Certification &

Qualification of Nondestructive Test Personnel

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

ANSI/ASNT CP-189 (2016) ASNT Standard for Qualification and

Certification of Nondestructive Testing Personnel (ANSI/ASNT CP-105-2006)

ASNT SNT-TC-1A (2020) Recommended Practice for Personnel

Qualification and Certification in Nondestructive Testing

ASME INTERNATIONAL (ASME)

ASME B46.1 (2019) Surface Texture, Surface Roughness, Waviness and Lay

ASTM INTERNATIONAL (ASTM)

ASTM A290/A290M (2016) Standard Specification for Carbon and Alloy Steel Forgings for Rings for Reduction Gears

ASTM A564/A564M (2019) Standard Specification for Hot-

Rolled and Cold-Finished Age-Hardening Stainless-Steel Bars and Shapes

ASTM B148 (2018) Standard Specification for

Aluminum-Bronze Sand Castings

ASTM E94/E94M (2017) Standard Guide for Radiographic Examination Using Industrial Radiographic Film

ASTM E390 (2020) Standard Reference

Radiographs for Steel Fusion Welds

ASTM E1030/E1030M (2021) Standard Test Method for

Radiographic Examination of Metallic Castings

ASTM E1032 (2021) Standard Test Method for

Radiographic Examination of Weldments

ASTM E1742/E1742M (2018) Standard Practice for Radiographic Examination

ASTM E1955 (2004; R 2020) Standard Radiographic

Examination for Soundness of Welds in Steel by Comparison to Graded ASTM E 390 Reference Radiographs

ASTM F468 (2016) Standard Specification for

Nonferrous Bolts, Hex Cap Screws, and Studs for General Use

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 10360-2 (2009) Geometrical Product Specifications

(GPS) Acceptance and Reverification Tests for Coordinate Measuring Machines (CMM) Part 2: CMMs Used for Measuring Linear Dimensions

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 1110-2-2610 (2013) Mechanical and Electrical Design for Lock and Dam Operating Equipment

1.3 SUBMITTALS

Submittals will be approved by either the point of contact (POC) or technical point of contact (TPOC).

The POC is:

Theodore Hecht Theodore.r.hecht@usace.army.mil 651-290-5415

The TPOC is:

Mike Holzer Michael.A.Holzer@usace.army.mil 651-290-5989

1.3.1 Radius Certification

Submit certification that the final machined hemispherical radii for each of the pintles and pintle bushings are within specified tolerances to the TPOC. The certification shall be signed by the machinist and a designated 3rd party Quality Assurance (QA) representative.

1.3.2 Welding Procedures

If welding is required, welding procedures are subject to approval by the government before proceeding with their use. The Contractor must submit the proposed welding procedures and proof of welder qualification for the proposed welding procedures to the Contracting Officer. The welding procedures shall include as a minimum, weld callouts, preheat treatment, interpass temperature, filler rod, welder machine and process used, polarity, and post heat treatment. If fusion welding is authorized by the government, it will need to be inspected using ASTM E94 / E94M 17 and/or ASTM standard E390 Standard Reference Radiographs for Steel Fusion Welds.

1.3.3 O-ring Seal Description

Submit catalog cuts for the O-rings to include method of splicing (bonding), material specifications, and dimensions.

1.3.4 Shop Drawings

Detailed shop drawings for pintles balls, pintle bushings, and all shop fabricated metal items, shall be submitted and approved prior to fabrication. The provided drawings may be submitted and suffice as approved shop drawings should there be no changes to the design during the fabrication process.

Material Orders

For materials that are not in stock substitute equal materials may be requested. Submit copies of purchase orders, mill orders, shop orders and work orders for materials prior to the use of the materials in the work.

1.4 SHIPPING, DELIVERY, STORAGE, AND HANDLING

The pintles and pintle bushing are required to be crated prior to shipping and or delivery. The crating containers must be constructed in a manner that allows for movement with a forklift. The contractor is responsible to repair any damage that may occur during shipping.

The contractor will deliver the finished pintles and pintle bushings (and the miscellaneous contractor-furnished parts) by April 1st, 2022, to:

US Army Corps of Engineers Lock and Dam 5A W679 State Hwy 35

Fountain City, WI 54629-7214

Notify the POC seven(7) days in advance of delivery the finished pieces. The stainless steel pintles shall be coated with temporary rust preventative compound (like "Cosmoline") after inspection and acceptance by the Government.

1.5 QUALITY ASSURANCE

Maintain records to certify compliance with all aspects of this contract and will make these records available in a timely manner should the POC request to see them.

1.6 ACCEPTANCE

Make the completed pieces available for final inspection by the Government at the Contractor's facility prior to any application of protective coatings and prior to shipment. Notify the POC at least 7 days in advance of when the pieces will be available for inspection.

The final products must be free from imperfections that may impair serviceability. Any products which show tolerance errors, distortion, fissures, notches, cracks, or cross threads, or variance from the specified condition may be cause for rejection and must be corrected at the Contractor's expense.

PART 2 PRODUCTS

2.1 MATERIALS

Submit system of identification which shows the disposition of specific lots of approved materials and fabricated items in the work, before completion of the contract.

2.1.1.1 Metals

Stainless steel, bronze, aluminum bronze and other metal materials used for fabrication shall conform to the requirements shown in the following paragraphs.

2.1.1.2 Aluminum Bronze Pintle Bushing

Provide a grease lubricated alloy bronze pintle bushing to the dimensions and tolerances indicated. For the bushing material use aluminum bronze alloy and conform to the requirements of ASTM B148, C95400 or ASTM B271 C95400. Pattern cast and machine the bushing or machine the bushing from a solid piece of material to acquire the shape and surface finishes indicated. Provide a surface finish of 16 micro-inches or better on the running bearing surface. Surface finishes are shown on the drawings in accordance with ASME B46.1.

Permanently label non-mating surface by engraving, stamping or laser etching a serial number. The serial numbers need to be least 12 font and

- -01, MVP-02...,

MVP-08).

Provide a debris seal of the dimensions and materials as indicated with the pintle bushing. Mate the bushing bearing surface with the corresponding pintle ball (serial numbers) through metrology methods and the use of a calibrated scanning probe coordinate measuring machine that meets the requirements of ISO 10360-2, by lapping mating components to achieve the indicated tolerances and compare with contact measurements or dye or tape to confirm uniform bearing contact. Test the contact area between the mating components, witnessed by the Government, to achieve a bearing contact area of 85 percent or better to be acceptable.

2.1.1.3 Stainless Steel Pintle Ball

Fabricate pintle ball(s) from steel conforming to ASTM A564/A564M TYPE 630 H1150, UNS S17400 (RC 28-37). Machine pintle ball(s) to meet the dimensions, surface finish and tolerances as indicated. Any casting patterns developed become property of the Government and must be packaged for long term storage with the pertinent part identification provided on the exterior packaging. The pintle ball will free float into the pintle bushing without distortion or altering the fit with the mating pintle bushing. Furnish removable lifting eyes with the pintle ball for lifting.

Mate the pintle ball bearing surface with the pintle bushing through metrology methods and the use of a calibrated scanning probe coordinate measuring machine that meets the requirements of ISO 10360-2, by lapping mating components to achieve the indicated tolerances and compared with contact measurements or dye or tape to confirm uniform bearing contact.

Test the contact area between the mating components to achieve a bearing contact area of 85 percent or better to be acceptable.

2.1.2 O-ring Seals

Install elastomeric NBR acrylonitrile butadiene (Buna-Nitrile or "Buna N") O-rings with the pintle assemblies. The O-rings shall be 70 Shore Durometer Hardness 0.50-inch circular cross-sectional diameter with pitch diameter to fit to the pintle bushing O-ring grooves as shown on the Contract Drawing.

The O-ring will have diameter of the seal of 15.75 inches. The O-ring loop may be spliced by bonding, provided the spliced cross section develops full tensile properties of the base material. The method of splicing shall be submitted for approval. The Contractor shall supply twelve (12) bonded O-rings (includes four spares).

2.1.3 Miscellaneous Materials.

Supply the following items. Fabricate to dimensions shown on the provided drawings.

2.1.3.1 Pintle Bushing Lifting Eyebolt

Galvanized steel, threads, minimum safe working load 2000 lbs.

These will be used for lifting pintle bushings in the field. Contractor shall supply four (4) eyebolts. Detail included on drawings.

2.1.3.2 Pintle Eyebolt

Forged steel, 3/4-10 UNC threads, minimum safe working load 2500 lbs. These will be used for lifting pintle balls in the field. Contractor shall supply four (4) eyebolts. Detail included on drawings.

2.1.3.3 Set screw: 3/4-10UNC x 2.50

Fabricate from bronze, ASTM F468, Alloy 655 (Silicon Bronze). Contractor shall supply forty-four (44) set screws (includes four spares). A detail for this item is included on drawings.

2.1.3.4 Set screw: 3/4-10UNC x 3.625

shall supply ten (10) set screws (includes two spares). A detail for this item is included on drawings.

2.1.3.5 Key screw: 5/8-11UNC x 1.50 Hex Head

shall supply ten (10) key screws (includes two spares). A detail for this item is included on drawings.

2.1.3.6 Key

Fabricate from 316 stainless steel. Contractor shall supply ten (10) keys (includes two spares) to the dimensions shown on the drawings.

PART 3 EXECUTION

3.1 PINTLE BUSHING MACHINING

Machine the hemisphere surface to obtain the surface finish and tolerance required. Location of hemisphere center point shall be reported to the Contracting Officer as a submittal.

Mill two annular grooves into each pintle bushing hemisphere. The upper annular groove is the grease return channel. The lower annular groove is the O-ring seal recess.

Drill and tap the existing bores on top of each pintle bushing to accept a threaded eye bolt.

Machine the semicircular grease grooves last after resurfacing the hemispheres. Deburr and relieve all sharp edges on milled grooves.

3.2 PINTLE MACHINING

Machine the hemisphere surface to obtain the surface finish and tolerance required. Location of hemisphere center point shall be reported to the Contracting Officer as a submittal.

Drill and tap the top of each pintle to accept the threaded eye bolt as indicated on the contract drawing. Machine (as required) the key slot on the lower lip of each pintle to match the dimensions given on the attached drawings.

3.3 PINTLE COMPONENT NONDESTRUCTIVE TESTING EXAMINATION

All Pintle bushings, balls and fabricated pintle components must have ANSI/ASNT CP-189, ASNT SNT-TC-1A, AIA/NAS NAS410 qualified personnel perform radiographic NDT testing in accordance with the guidelines, practices and applicable testing standards set forth in ASTM E94/E94M, ASTM E390, ASTM E1742/E1742M, ASTM E1030/E1030M, and ASTM E1032. Also test the pintle components by magnetic particle NDT methods in accordance with supplementary requirement S3.1 of ASTM A290/A290M. Other NDT methods are subject to Government approval. Radiographic acceptance criteria for castings satisfies the minimum severity level requirements for a Grade I condition as defined by ASTM E1955.

Any cracks found are unacceptable and reason for immediate rejection.

Evaluate all relevant indications greater than 1/16 inch in length present on radiographic films against the specified acceptance criteria. Where the length of each indication (li) within an area of interest and along a continuous straight line oriented in the direction of interest are measured. If the distance between two indications is smaller in length than the length of the smaller indication, then both indications must be added and treated as a single indication to include the distance of both indications as well as the distance between the indications. The total indication length is obtained as the sum of all indication lengths on a straight line within the area of interest. The maximum total indication length (lim) on any such single straight line is used to assess acceptance of the casting being evaluated.

This maximum total indication length (lim) is divided by the feature length (Lf), where (Lf) equals 1-1/8 inches, to calculate the indication fraction F (F = lim / Lf). The value of indication fraction F must be acceptable for values less than a Level I F=0.1. Provide 7-day advance notice of the NDT testing and perform all testing in the presence of the POC. If testing and certification is not performed in the presence of the POC, the Government reserves the right to perform independent quality verification, at the expense of the Contractor, and the acceptable total indication length (lim) for the acceptable indication fraction Level will be increased by 1/16 inch for the calculation to account for reproducibility in the evaluation. The manufacturer must certify in writing that the inspection was performed in accordance with the requirements specified and found to meet or exceed the requirements of the specified inspection level.

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