LD2 WM Pintle SOW_2023-10-13_Final.pdf

SCOPE OF WORK

PINTLE AND BUSHING FABRICATION

PART 1 GENERAL

1.1 SCOPE

Fabrication of four (4) pintles balls, four (4) 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 must have an inner bearing surface 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

d. Supply specified lifting eyebolts, 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 must conform to the 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 5) NAS Certification &

Qualification of Nondestructive Test Personnel

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI/MSS SP-55 (2011) Quality Standard for Steel Castings for Valves, Flanges, Fittings, and Other Piping Components - Visual Method for Evaluation of Surface Irregularities

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

ANSI/ASNT CP-189 (2020) 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 B1.1 (2019) Unified Inch Screw Treads (UN, UNR, and UNJ Thread Forms

ASME B1.20.1 (2013, R2018) Pipe Threads, General Purpose (Inch)

ASME B18.15 (2015, R2021) Forged Eyebolts

ASME B18.21.1 (2009) Washers: Helical Spring-Lock, Tooth Lock, and Plain Washers

ASME B46.1 (2019) Surface Texture (Surface

Roughness, Waviness, and Lay)

ASTM INTERNATIONAL (ASTM)

ASTM A148/A148M (2020; E 2020) Standard Specification for Steel Castings, High Strength, for Structural Purposes

ASTM A473 (2023a) Standard Specification for

Stainless Steel Forgings

ASTM A489 (2018) Standard Specification for Carbon Steel Eyebolts

ASTM A564/A564M (2019a) 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 B271/271M (2018) Standard Specification for Copper-Base Alloy Centrifugal Castings

ASTM E94/E94M (2022) Standard Guide for Radiographic

Examination Using Industrial Radiographic Film

ASTM E186 (2020) Standard Reference Radiographs for Heavy-Walled (2 to 4 1/2in. (50.8 to 114 mm)) Steel Castings

ASTM E272 (2021) Standard Reference Radiographs for High-Strength Copper-Base and Nickel-Copper Alloy Castings

ASTM E280 (2021) Standard Reference Radiographs for Heavy-Walled (4 1/2 to 12in. (114 to 305 mm)) Steel Castings

ASTM E390 (2020) Standard Reference Radiographs for Steel Fusion Welds

ASTM E446 (2020) Standard Reference

Radiographs for Steel Castings Up to 2 in. in Thickness

ASTM E1030/E1030M (2021) Standard Practice for

Radiographic Examination of Metallic Castings

ASTM E1032 (2019) Standard Practice for

Radiographic Examination of Weldments Using Industrial X-Ray Film

ASTM E1417/E1417M (2021) Standard Practice for

Liquid Penetrant Testing

ASTM E1742/E1742M (2018) Standard Practice for

Radiographic Examination

ASTM E1955 (2020) Standard Radiographic Examination for Soundness of Welds in Steel by Comparison to Graded ASTM E390 Reference Radiographs

ASTM F468 (2023) Standard Specification for

Nonferrous Bolts, Hex Cap Screws, Socket Head 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

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

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following:

SD-02 Shop Drawings

Pintle Balls; G, ME Pintle Bushings; G, ME Fabricated Miscellaneous Materials; G, ME Purchased Miscellaneous Materials; G, ME

SD-06 Test Reports

Registered Radiographic Interpretation Report With Films; G, ME

SD-07 Certificates

Registered Radiographic Interpreter; G, ME

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

POC: Theodore Hecht

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

TPOC: 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 must 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 must include as a minimum, weld callouts, preheat treatment, interpass temperature, filler rod, welder machine and process used, polarity, and post heat treatment. Fusion welding should not be used unless it is deemed necessary and must be authorized by USACE. If fusion welding is authorized by USACE, it must be inspected using ASTM standard E390 Standard Reference Radiographs for Steel Fusion Welds.

1.3.3 Shop Drawings

Detailed shop drawings for pintles balls, pintle bushings, and all shop fabricated metal items, must 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.

1.3.4 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 substitute materials prior to the use of the materials in the work.

1.4 SHIPPING, DELIVERY, STORAGE, AND HANDLING

The Pintle Balls are required to be inspected by the Government prior to mailto:Michael.A.Holzer@usace.army.mil being crated and prior to shipping and/or delivery. The stainless steel pintle components must be coated with an appropriate temporary rust preventative compound after inspection but prior to acceptance by the Government and prior to shipment.

The pintles and pintle bushings 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 and marked on four (4) sides with the contract award number, description of contents, number of pieces, and weight.

Greased pintle balls shall be packaged in sets of components. The Contractor must submit a greased pintle ball packing list prior to shipping for the contents of each crate to the Contracting Officer and the Operations point of Contact, Mike Holzer, at least 15 days prior to shipment, via email. The Contractor is responsible for notifying the Contracting Officer forty-five

(45) days prior to shipping the finished pieces. The Contractor must notify the POC seven (7) days in advance of delivery the finished pieces. 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 June 1, 2024, to:

US Army Corps of Engineers Fountain City Service Bay Attn: Mike Holzer 431 North Shore Drive Fountain City, WI 54629

1.5 QUALITY ASSURANCE

The Contractor will be responsible to maintain records to certify compliance with all aspects of this contract and must 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 seven (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, 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 Metals

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

2.1.1.1 Aluminum Bronze Pintle Bushing

Fabricate pintle bushing(s) from an aluminum bronze alloy material which conforms to the requirements of ASTM B148, C95400 or ASTM B271 C95400. Heat treat in accordance with TABLE 3 in ASTM B148. Machine pintle bushing(s) to meet the dimensions, surface finish and tolerances as indicated in the attached drawings. 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 at least 12 font and follow the convention XXXXXXX-PN-001, where XXXXXXX is the contract number, PN designates pintle, and the last three numbers are the individual identifier (example: 1111111-PN-001, 1111111-PN-002..., 1111111-PN-008).

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, compare with contact measurements or dye or tape to confirm uniform bearing contact. The contact area between the mating components must be tested to achieve a bearing contact area of 85 percent or better to be acceptable. This test must be witnessed by the Government, and the Contractor will notify the Government seven (7) days prior to testing. In the event the Government declines to attend, the testing results will be sent to the Contracting Officer promptly for Government review.

All threads must be in accordance with ASME B1.1 or ASME B1.20.1, as appropriate.

2.1.1.2 Stainless Steel Pintle Ball

Fabricate pintle ball(s) from hot-rolled stainless steel which conforms to the requirements of ASTM A564/A564M TYPE 630 H1150, UNS S17400. Machine pintle ball(s) to meet the dimensions, surface finish and tolerances as indicated in the attached drawings. Any dies or 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, 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. This test must be witnessed by the Government, and the Contractor will notify the Government seven (7) days prior to testing. The maximum static bearing pressure for the pintle ball must not exceed 9000 psi when a normal load 625,510 pounds is applied at an angle of 36.22 degrees from horizontal or 18000 psi during dynamic operation. All threads must be in accordance with ASME B1.1.

2.1.2 Miscellaneous Materials.

Supply the following items. Fabricate to dimensions shown on the provided drawings. Variances from the below listed requirements are allowed only if specifically approved by the Contracting Officer.

All eyebolt and set screws must be in accordance with ASME B1.1, ASME B18.15, and ASTM A489, as appropriate.

2.1.2.1 Pintle Eyebolt

Zinc-Plated steel, ASTM A489, 3/4”-10 UNC threads, minimum safe working load 5000 lbs, minimum thread length 2”, Minimum lifting hole diameter 1.50”. Certify the eyebolts fit the pintle threads. These will be used for lifting pintle balls in the field. Contractor will supply two (2) eyebolts.

2.1.2.2 Set Screw - Type 1: 3/4”-10 UNC x 2.50”

Purchase or fabricate from bronze, ASTM F468, Alloy 655 (Silicon Bronze).

Contractor will supply eighteen (18) type 1 set screws (includes two spares). A detail for this item is included on drawings.

2.1.2.3 Set Screw - Type 2: 3/4”-10 UNC x 3.625”

Contractor will supply five (5) type 2 set screws (includes one spare). A detail for this item is included on drawings.

2.1.2.4 Key Screw: 5/8”-11 UNC x 1.50” Hex Head

Contractor will supply five (5) key screws (includes one spare). A detail for this item is included on drawings.

2.1.2.5 Key

Fabricate from 316 stainless steel. Contractor will supply five (5) keys (includes one spare) 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 must be recorded and reported to the Contracting Officer as a submittal.

Drill and tap the bore on top of each pintle bushing to accept a 1/2"- 14 NPT grease pipe. This bore will not be used for lifting. Drill and tap two (2) 1/2”-13 UNC handling holes into the bottom of the bushing per drawings. Drill and tap five (5) 5/8”-11 UNC holes for set screws per drawings. Machine the semicircular grease grooves last, after resurfacing the hemispheres. Deburr and relieve all sharp edges on milled grooves.

"The aluminum bronze bushing is to be press fit into the pintle socket and secured by bolting to the socket. The amount of press fit of the bushing in the socket should be kept minimal" in accordance with USACE EM 110-2-2610.

This is to "prevent any alteration of the machined fit between the bushing and pintle ball after assembly." The outer pintle bushing diameter must be 1'-6" +0.001/-0.000 after machining. The pintle socket inner diameter must be 1'-6" +0.001/-0.000. This must result in a modified FN1 fit. Confirmation of dimensions for the pintle socket may be obtained by contacting the POC.

3.2 PINTLE MACHINING

Machine the hemisphere surface to obtain the surface finish and tolerance required. Location of hemisphere center point must be recorded and 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

3.3.1 Castings and Forgings

Each casting and forging must bear cast or stamped mark numbers. Castings and forgings weighing more than 500 pounds must also bear cast or stamped heat numbers. Dimensions shown on approved detail drawings will be finished dimensions. Castings and forgings that are warped or otherwise distorted or that are oversized to an extent that will interfere with proper fit with other parts of other structures will be rejected. The structure of metal in castings and forgings must be homogeneous and free from excessive nonmetallic inclusions. Excessive segregation of impurities or alloys at critical points in castings and forgings will be cause for rejection.

Repairs to castings and forgings will not be made without prior approval.

Minor surface imperfections not affecting the strength of the casting or forging may be welded in the "Green" only if approved. Surface imperfections will be considered minor when the depth of the cavity prepared for welding is the lesser of 20 percent of the actual wall thickness or 1 inch. Defects other than minor surface imperfections may be welded only when specifically authorized by the Government and meet the following requirements:

(1) The defects have been entirely removed and are judged not to affect the strength, use, or machineability of the casting or forging when properly welded and stress relieved.

(2) The proposed welding procedure, stress relief, and method of examination of the repair work have been submitted and approved by the Contracting Officer.

3.3.2 Welding of Steel Forgings

Unsound material must be removed from the surfaces of steel forgings to be incorporated into welded connections by chipping, machining, air-arc gouging or grinding. Major connections designed for the transfer of stresses must not be welded if the temperature of the forging is lower than 100 degrees Fahrenheit. Forgings containing over 0.35 percent carbon or over 0.75 percent manganese must be preheated to a temperature not to exceed 450 degrees Fahrenheit, and welding must be accomplished while the forgings are maintained at a temperature above 350 degrees Fahrenheit. Welding will not be permitted on forgings containing carbon in excess of 0.45 percent, except when authorized in writing. Forgings requiring welded repairs after the first annealing and forgings involving welding fabrication must be stress-relieved annealed prior to receiving final machining unless otherwise permitted. The proposed welding procedure, stress relief, and method of examination of the repair work must be submitted and approved by the Contracting Officer.

3.3.3 Tests, Inspections, and Verifications

The Contractor must have all required material tests and analysis performed and certified by an approved laboratory to demonstrate that the chemical requirements and the mechanical requirements for the materials for the pintle bearing assembly components are in conformance with the specifications. These tests and analytics must be performed after castings and forgings are completed and before machining of the items has started. Test reports must be submitted to the Contracting Officer immediately after completion of the testing. Tests must be conducted in the presence of the Contracting Officer if requested by the Government. The Contractor must furnish specimens and samples for additional independent tests and analyses upon request of the Contracting Officer. Specimens and samples must be properly labeled and prepared for shipment.

3.3.4 Nondestructive Testing

All parts associated with the pintle assembly will be inspected and tested as outlined in paragraph 3.3.5, and all costs associated with these will be included in the original contract cost.

When doubt exists as to the soundness of any material part, such part may be subjected to any additional form of nondestructive testing as determined by the Contracting Officer. This may include ultrasonic, dye penetrant, x-ray, gamma ray, or any other test that will thoroughly examine the part in question. The cost of such investigation will be borne by the Government.

Any cracks or defects will be cause for immediate rejection and rejected parts shall be replaced and retested at the Contractor's expense.

3.3.5 Inspection of Castings and Forgings

Radiographic inspections must be performed by a Registered Radiographic Interpreter. Submit copies of certificates showing evidence of qualifications or certifications for radiographic interpreter. Provide a Registered Radiographic Interpretation Report With Films to the Contracting Officer for review and approval.

Perform visual and radiographic inspections of the bushings and pintle balls.

Visual inspection and acceptance criteria in accordance with MSS SP-55.

Procedures for making, evaluating, and reporting radiographic inspections must conform to the requirements of ASTM E94/E94M and ASTM E1030/E1030M.

The radiographic shooting diagram for pintle bushings and pintle balls must be in accordance with ASTM E94/E94M. The castings and forgings are unacceptable if shown to have defects greater than the following severity levels:

Pintle Bushing; ASTM E272 (Cu and Ni based alloy castings) Radiographic Indication Acceptance Criteria Description Code Severity Level Gas Porosity A 3 Sand Inclusions Ba 3 Dross Inclusions Bb 2 Shrinkage, Linear Ca 3 Shrinkage, Feathery Cd 3 Shrinkage, Spongy Cd 3 Cracks None Allowed Hot Tears None Allowed Chaplets None Allowed

Pintle Ball; ASTM E446 (thickness up to 2 inches) Radiographic Indication Acceptance Criteria Category Description Severity Level A Gas Porosity 3 B Sand and Slag Inclusions 2 C Shrinkage

CA 2

CB 1

CC 2

CD 1

D Cracks None Allowed E Hot Tears None Allowed F Inserts None Allowed

Pintle Ball; ASTM E186 (thickness 2 to 4 ½ inches) Radiographic Indication Acceptance Criteria Category Description Severity Level A Gas Porosity 4 B Sand and Slag Inclusions 3 C Shrinkage Type 1 3 Type 2 3 Type 3 3 D Cracks None Allowed E Hot Tears None Allowed F Inserts None Allowed, unfused

Pintle Ball; ASTM E280 (thickness 4 ½ to 12 inches) Radiographic Indication Acceptance Criteria Category Description Severity Level A Gas Porosity 4 B Sand and Slag Inclusions 4 C Shrinkage Type 1 3 Type 2 3 Type 3 3 D Cracks None Allowed E Hot Tears None Allowed F Inserts None Allowed

3.3.5.1 Pintle Balls, Pintle Bushings, and Components

All pintle bushings, balls and fabricated pintle components must have the following NDT testing performed.

a. Pintle ball: radiographic testing per ASTM E94/E94M, ASTM E1742/E1742M, ASTM E1030/E1030M, and ASTM E1032.

b. Pintle bushing: radiographic testing per ASTM E94/E94M, ASTM E1742/E1742M, ASTM E1030/E1030M, and ASTM E1032.

c. Set screws, key screws, and keys: liquid penetrant testing per ASTM E1417/E1417M, Type 1 - Fluorescent dye, Sensitivity Level 3 – High, no cracks allowed

Only ANSI/ASNT CP-189, ASNT SNT-TC-1A, AIA/NAS NAS410 qualified personnel may perform radiographic NDT testing. Radiographic acceptance criteria for castings and forgings 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 or forging 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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