W912P519T0012_TSpecs_Amendment_0003_2019_04_24.pdf

Air Seal Replacement Kentucky Lock W912P519T0012 Amendment 0003 Livingston County, Kentucky

SECTION TABLE OF CONTENTS

DIVISION 05 - METALS

SECTION 05 59 13

FABRICATION OF HYDRAULIC STEEL STRUCTURES

PART 1 GENERAL

1.1 SCOPE

1.1.1 General

1.1.2 Base Contract

1.1.2.1 Air Seal Assemblies - Required 4

1.1.2.2 6" dia. Ball Valves - Required 4

1.1.2.3 Valve Stem Assemblies - Required 4

1.2 REFERENCES

1.3 QUALITY ASSURANCE

1.3.1 Detail Drawings

1.3.2 Structural Members

1.3.2.1 Certification and Qualification

1.3.2.2 Material Handling

1.3.2.3 Tack Welds and Temporary Welds

1.3.2.4 Welding Processes

1.3.2.5 Weld Inspection

1.3.2.6 Repair Welding

1.4 SUBMITTALS

1.5 DELIVERY, STORAGE, AND HANDLING

1.6 VETERANS EMPLOYMENT EMPHASIS FOR U.S. ARMY CORPS OF ENGINEERS

CONTRACTS

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Structural Steel

2.1.2 Stainless Steel Plates, Pipe and Bolts

2.1.3 Ball Valves

2.1.3.1 General

2.1.3.2 Valve Stem

2.1.3.3 Valve Stem Supports

2.1.4 Flanged Elbows

2.1.5 Anchor Bolts

2.1.6 U Bolts

2.1.7 Rubber Seals

2.1.8 Magnesium Anodes

2.2 FABRICATION

2.2.1 Structural Fabrication

2.2.1.1 Dimensional Tolerances for Structural Work

2.2.1.2 Structural Steel Fabrication

2.2.2 Assembly

2.2.3 Welded Connections

2.2.3.1 Welding Procedure

2.2.3.2 Welder Performance Qualification of Welders and Welding

Operators

SECTION 05 59 13 Page 1

2.2.3.3 Welding Process

2.2.3.4 Welding Technique

2.2.3.4.1 Filler Metal

2.2.3.4.2 Preheat and Interpass Temperature

2.2.3.4.3 Stress-Relief Heat Treatment

2.2.3.5 Workmanship

2.2.3.5.1 Preparation of Base Metal

2.2.3.5.2 Tack and Temporary Welds

2.2.3.5.3 Tack Welds

2.2.3.5.4 Weld Access Holes

2.2.3.5.5 Weld Backing Removal

2.2.3.5.6 Weld Backing Material Other Than Steel

2.2.4 Bolted Connections

2.2.4.1 Bolts, Nuts, and Washers

2.2.4.2 Bolt Holes

2.2.5 Miscellaneous Provisions

2.2.5.1 Weldments

2.2.5.2 Drain Holes

2.2.6 Shop Assembly

2.2.7 Seals

2.3 TESTS, INSPECTIONS, AND VERIFICATIONS

2.3.1 Nondestructive Testing (NDT)

2.3.2 Inspection of Structural Steel Welding

2.3.2.1 Visual Examination

2.3.2.2 Nondestructive Examination

2.3.2.2.1 Testing Agency

2.3.2.2.2 Examination Procedure

2.3.2.2.3 Acceptability of Welds

2.3.2.2.4 Examination Procedures

2.3.2.2.4.1 Ultrasonic Testing (UT)

2.3.2.2.4.2 Magnetic Particle Inspection (MT)

2.3.2.2.4.3 Dye Penetrant Inspection (PT)

2.3.3 Welds to be Subject to Nondestructive Examination

2.3.3.1 Structural Steel Members

2.3.3.2 Structural Steel Member Fillet Welds and Partial

Penetration Welds

2.3.4 Test Coupons

2.3.5 Supplemental Examination

2.3.6 Structural Steel Welding Repairs

2.3.7 Control Dimensions

PART 3 EXECUTION

3.1 INSTALLATION

3.1.1 Cleaning

3.1.2 Alignment and Setting

3.1.3 Field Installation

3.2 PROTECTION OF FINISHED WORK

3.3 PAINTING

3.4 SHOP INSPECTION

-- End of Section Table of Contents --

SECTION 05 59 13 Page 2

SECTION 05 59 13

FABRICATION OF HYDRAULIC STEEL STRUCTURES

PART 1 GENERAL

1.1 SCOPE

1.1.1 General

The work covered by this section consists of furnishing all labor, materials and equipment, and performing all work necessary and required to complete the air seal assemblies and valve stem assemblies as specified herein and on the drawings. All work shall be performed in strict accordance with this section of the specifications and the applicable drawings, and shall be subject to the terms and conditions of the contract.

Contractor shall also deliver the equipment to Kentucky Lock Project.

Installation shall be performed by others.

1.1.2 Base Contract

All air seals shall be assembled in shop by the Contractor.

1.1.2.1 Air Seal Assemblies - Required 4

Provide four air seal assemblies. Each air seal assembly shall include structural plates, rubber seals, jack screws, jack arms, jack pins, magnesium anodes, steel blocks, steel block cover plants, hardware, 2" dia.

ball valves, 90 degree elbows (2" dia. elbow and 6" dia. elbow) with 2 gaskets for each elbows, and all required accessories for a complete air seal assembly.

Spare parts - Contractor shall also provide the following spare parts:

a. 16 magnesium anode assemblies that include anodes, studs, nuts, washers, etc.

b. 16 steel blocks MK 64274-4-1.

c. 16 cover plates MK 64274-4-2.

1.1.2.2 6" dia. Ball Valves - Required 4

Provide four 6" dia. ball valves along with stainless steel bolts for flanged connection, 12" dia. hand wheel and hand wheel connection bolt.

Flanged gaskets are covered in air seal assemblies.

1.1.2.3 Valve Stem Assemblies - Required 4

Provide four valve stem assemblies that include valve stem supports, valve stem extensions, wrench extensions (required 2), stainless steel U-bolts, stainless steel anchor bolts and other required accessories.

SECTION 05 59 13 Page 3

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.

AMERICAN WATER WORKS ASSOCIATION (AWWA)

AWWA C110/A21.10 (2012) Ductile-Iron and Gray-Iron Fittings for Water

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2015; Errata 1 2015; Errata 2 2016) Structural Welding Code - Steel

ASME INTERNATIONAL (ASME)

ASME B16.34 (2017) Valves - Flanged, Threaded and Welding End

ASTM INTERNATIONAL (ASTM)

ASTM A193/A193M (2016) Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service and Other Special Purpose Applications

ASTM A240/A240M (2017) Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications

ASTM A276/A276M (2017) Standard Specification for Stainless Steel Bars and Shapes

ASTM A312/A312M (2017) Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes

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

ASTM A351/A351M (2016) Standard Specification for Castings, Austenitic, for Pressure-Containing Parts

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

ASTM A490 (2014a) Standard Specification for Structural Bolts, Alloy Steel, Heat Treated, 150 ksi Minimum Tensile Strength

ASTM A514/A514M (2014) Standard Specification for High-Yield-Strength, Quenched and Tempered Alloy Steel Plate, Suitable for Welding

SECTION 05 59 13 Page 4

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

ASTM A563 (2015) Standard Specification for Carbon and Alloy Steel Nuts

ASTM A709/A709M (2018) Standard Specification for Structural Steel for Bridges

ASTM D2000 (2012; R 2017) Standard Classification System for Rubber Products in Automotive Applications

ASTM E165/E165M (2012) Standard Practice for Liquid Penetrant Examination for General Industry

ASTM E709 (2015) Standard Guide for Magnetic Particle Examination

ASTM F3125/F3125M (2015a) Standard Specification for High Strength Structural Bolts, Steel and Alloy Steel, Heat Treated, 120 ksi (830 MPa) and 150 ksi (1040 MPa) Minimum Tensile Strength, Inch and Metric Dimensions

ASTM F436 (2011) Hardened Steel Washers

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS

INDUSTRY (MSS)

MSS SP-72 (2010a) Ball Valves with Flanged or Butt-Welding Ends for General Service

1.3 QUALITY ASSURANCE

1.3.1 Detail Drawings

If Contractor deviates from the contract drawings, then they shall need to submit detail drawings for metalwork and machine work, prior to fabrication, include within the detail drawings catalog cuts, templates, fabrication and assembly details and type, grade and class of material as appropriate.

Drawings must also show the connection details for valve stem assembly.

1.3.2 Structural Members

Structural steel must be ASTM A709/A709M, grade as specified or shown on the drawings. Contractor must submit the material test report for government approval.

1.3.2.1 Certification and Qualification

Welders and welding operators shall meet the applicable requirements of AWS D1.1/D1.1M.

1.3.2.2 Material Handling

Material handling and preparation, including thermal cutting, preparation

SECTION 05 59 13 Page 5 of base metal, and straightening, curving, cambering shall meet the applicable requirements.

1.3.2.3 Tack Welds and Temporary Welds

Locate all welds within the joint and meet the requirements of

AWS D1.1/D1.1M.

1.3.2.4 Welding Processes

Perform welding of structural steel by an electric arc welding process using a method which excludes the atmosphere from the molten metal and conforms to the applicable provisions of AWS D1.1/D1.1M. Minimize residual stresses, distortion and shrinkage from welding.

1.3.2.5 Weld Inspection

Qualify all inspectors and NDT technicians as required. Test all butt joints with UT and RT. Inspection procedures and documentation are as specified in the applicable sections of AWS D1.1/D1.1M. Strictly adhere to cooling times.

1.3.2.6 Repair Welding

Classify repair welds as "critical repairs" or "non-critical repairs" for all repair welding. Repair procedures shall follow the minimum provisions unless specified otherwise. Repair procedures must be qualified and approved and subject to the same QA/QC inspection requirements as other welds. Minimum preheat for repair welding shall be as defined in AWS D1.1/D1.1M. All weld repairs shall be in accordance with AWS D1.1/D1.1M Section 12.17.3 and shall be approved by the Engineer of Record.

1.4 SUBMITTALS

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

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

SD-02 Shop Drawings

Detail Drawings; G, ECD

SD-03 Product Data

U-Bolts; G Elbows; G Ball Valves; G Stainless Steel Bolts; G Anchor Bolts; G Magnesium Anodes; G Rubber Seals; G

SD-04 Samples

SD-06 Test Reports

SECTION 05 59 13 Page 6

Ndt Reports; G

SD-07 Certificates

Welder Performance Qualification Of Welders And Welding Operators;

G

SD-08 Manufacturer's Instructions

Delivery/Shipping Plan; G

SD-09 Manufacturer's Field Reports

1.5 DELIVERY, STORAGE, AND HANDLING

Notify the Contracting Officer at least 14 calendar days in advance of delivery of the structures. Shipping of the structures shall be at the Contractor's expense. The structures shall be arranged on the delivery vehicles such that no damage occurs during shipping. All sling lifting lugs shall be directed up. Submit a Delivery/Shipping Plan showing orientation and locations of structures on the delivery vehicles prior to shipment for Government approval. Submit drawings providing descriptions of methods of delivering the completed structural units, including details for support during shipment to prevent distortion or other damages, and orientation and location of the structure on transport equipment.

Contractor shall contact the Facilities Manager below at least 14 calendar days prior to the delivery date to set up the delivery date and location.

Delivery will be made from Monday thru Thursday, 0600 - 1630 except Federal Holidays. Cost of shipping shall be included in the contract. Government shall provide the crane /forklift and crane operator as required to unload the air seal assemblies off the Contractor's delivery truck.

Barkley Lock POC Caleb Skinner 265 Barkley Dam Road Grand Rivers, KY 40245 Phone: 270-362-4226 Email: John.C.Skinner@usace.army.mil

1.6 VETERANS EMPLOYMENT EMPHASIS FOR U.S. ARMY CORPS OF ENGINEERS CONTRACTS

In addition to complying with the requirements outlined in FAR Part 22.13, FAR Clause 52.222-35 EQUAL OPPORTUNITY FOR VETERANS, FAR Clause 52.222-37

EMPLOYMENT REPORTS ON VETERANS, DFARS 222.13 SPECIAL DISABLED AND VIETNAM

ERA VETERANS, and Department of Labor regulations, U.S. Army Corps of Engineers (USACE) contractors and subcontractors at all tiers are encouraged to promote the training and employment of U.S. veterans while performing under a USACE contract. While no set-aside, evaluation preference, or incentive applies to the solicitation or performance under the resultant contract, USACE contractors are encouraged to seek out highly qualified veterans to perform services under this contract. The following resources are available to assist USACE contractors in their outreach efforts:

a. U.S. Department of Labor Veterans employment: www.vets.gov/

b. Federal veteran employment information: www.fedshirevets.gov/index.aspx

SECTION 05 59 13 Page 7

c. Veterans’ Employment and Training Service (VETS):

http://www.dol.gov/vets/

d. Veterans Opportunity to Work (VOW) Program: http://benefits.va.gov/vow/

e. U.S. Army Warrior Transition Command Employment Index:

http://www.wct.army.mil/modules/employers/index.html

f. Hiring Our Heroes initiative:

www.uschamberfoundation.org/hiring-our-heroes

g. Guide to Hiring Veterans:

https:://obamawhitehouse.archives.gov/sites/default/files/docs/white_house_business_

- guide_to_hiring_veterans_0.pdf

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Structural Steel

Unless otherwise noted, air seal assemblies shall be fabricated from

ASTM A709/A709M.

For the clamp bars and spacer bars (MK 64W274-2-5, 64W274-2-6, 64W274-2-7, 64W274-2-8, and 64W274-2-9), ASTM A709/A709M or ASTM A36/A36M can be used.

2.1.2 Stainless Steel Plates, Pipe and Bolts

Stainless steel plates and bars: ASTM A240/A240M or ASTM A276/A276M.

Stainless steel pipe: ASTM A312/A312M Stainless steel bolts: Unless otherwise noted, Contractor shall provide stainless steel bolts in accordance with ASTM A193/A193M, Gr. B8.

Furnish bolts with stainless steel nuts and washers. Provide product data for approval.

2.1.3 Ball Valves

Submit product data for all ball valves.

2.1.3.1 General

Provide 6" dia. and 2" dia. stainless steel ball valves, standard port, as shown on the contract drawings. Valves shall have flanged connection in accordance with ASME B16.34 and MSS SP-72. Valves shall have ASTM class 150RF. Provide stainless steel bolts, nuts and washer for flange connection. Materials shall be as the follow:

Valve body: stainless steel ASTM A351/A351M, CF8M, Unibody.

Ball, stem and packing gland: stainless steel ASTM A276/A276M Stem seal: Polytetrafluoroethylene (PTFE) Seat and body seal: Reinforced Polytetrafluoroethylene (RPTFE) Bolts for flange connection: Stainless steel ASTM A193/A193M, Gr. B8M.

Furnish bolts with nut and washers.

2" dia. ball valves shall have stainless steel lever. 6" dia. ball valves shall have handle adapter to work with the valve stem assembly. All ball valves shall have a 90 degree turn for open and close. Both 6" dia. and 2" dia. valves shall have unibody. Max. length for the 6" ball valve shall be

SECTION 05 59 13 Page 8

10.5".

2.1.3.2 Valve Stem

Stainless steel valve stems shall be fabricated as shown on the shop drawing. Each valve stem is to be split into two (2) segments of 40 feet or four (4) segments of 20 feet. Connections of segments can be done by mechanical connection or welding. Submital shop drawings that show connection details for approval. Valve stem assembly shall be conducted in the field by the government personnel.

2.1.3.3 Valve Stem Supports

Stainless steel supports for valve steam shall be fabricated as shown on the shop drawings. Provide stainless steel standard U-bolts and anchor bolts as shown on the contract drawing. One (1) U-bolt and two (2) anchor bolts shall be required for valve stem support. Provide stainless pipe operating handle as shown on the contract drawing.

2.1.4 Flanged Elbows

Provide 90 degree ductile iron ASTM A536 elbows for valve connection.

Provide each elbow with hardware and 2 rubber gaskets. One gasket for elbow connecting to the 7/8" structural plate and another gasket for elbow connection to the ball valve. Flanged fittings shall be manufactured in accordance with AWWA C110/A21.10, Class 125. Provide product data for approval. Furnish all flanged elbows with stainless steel bolts, nuts and washers. stainless steel bolts shall be in accordance with ASTM A193/A193M, Gr. B8.

2.1.5 Anchor Bolts

Provide expansion type anchor made from 304 or 316 stainless steel that are suitable for seismic and cracked concrete applications. Nuts and washers shall also be made from stainless steel. Anchor bolts shall be Hilti, Kwik Bolt 3 Expansion Anchor or approved equal.

2.1.6 U Bolts

Each stainless steel standard U-bolt shall be furnished with four (4) hex.

nuts and four (4) washers. Thread size shall be 3/8"-16 or as recommended by the U-bolt manufacturer. Submit product data of U-bolts for approval.

2.1.7 Rubber Seals

Provide neoprene rubber seals to be used for service in moderate levels of oil, petroleum, ozone, acids, grease, etc. Rubber seals shall be in accordance with ASTM D2000 and shall meet the following requirements:

a. Color: Black

b. Durometer: 40

c. Service Temperature: -20 to +170 deg. F

d. Tensile Strength (minimum): 800 psi

e. Ultimate Elongation (min.): 300%

f. Thickness: rubber shall be made from the 2" thick plate.

2.1.8 Magnesium Anodes

Contractor shall provide and install magnesium anodes for corrosion

SECTION 05 59 13 Page 9 protection. Magnesium anodes shall have the nominal 55% current efficiency in seawater and the current capacity of about 550 amp-hr./lb. Chemical composition include Mg, Al, Mn, Zn, Si, Cu, Ni Fe and others. Each anode weights 2 lbs with the diameter of 4" or 5". Provide mounting kits that include 1/2" stainless steel stud, 1/2" flex-loc nut, plastic stud protector, washer, rubber washer, rubber gasket and gasket compound.

Magnesium anodes shall be as manufactured by MESA (Tulsa, OK), Sizes E2, 2R5 or approved equal.

2.2 FABRICATION

2.2.1 Structural Fabrication

Material must be straight before being laid off or worked. Perform straightening, if necessary, by methods that will not impair the metal.

Sharp kinks or bends will be cause for rejection of the material. Material with welds will not be accepted except where welding is definitely specified, indicated or otherwise approved. Make bends using approved dies, press brakes or bending rolls. Where heating is required, take precautions to avoid overheating the metal and allow it to cool in a manner that will not impair the original properties of the metal. Proposed flame cutting of material, other than structural steel, is subject to approval and must be indicated on detail drawings. Shearing shall be accurate and all portions of the work neatly finished. Make corners square and true unless otherwise shown. Fillet re-entrant cuts to a minimum radius of 3/4 inch unless otherwise approved. Provide finished members free of twists, bends and open joints. Tighten bolts, nuts and screws.

2.2.1.1 Dimensional Tolerances for Structural Work

Material must be straight before being laid off or worked. Perform straightening, if necessary, by methods that will not impair the metal.

Sharp kinks or bends will be cause for rejection of the material. Material with welds will not be accepted except where welding is definitely specified, indicated or otherwise approved. Make bends using approved dies, press brakes or bending rolls. Where heating is required, take precautions to avoid overheating the metal and allow it to cool in a manner that will not impair the original properties of the metal. Proposed flame cutting of material, other than structural steel, is subject to approval and must be indicated on detail drawings. Shearing shall be accurate and all portions of the work neatly finished. Make corners square and true unless otherwise shown. Fillet re-entrant cuts to a minimum radius of 3/4 inch unless otherwise approved. Provide finished members free of twists, bends and open joints. Tighten bolts, nuts and screws.

2.2.1.2 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. Prepare surfaces and edges in accordance with AWS D1.1/D1.1M, Subclause 3.2. 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. Chip, grind or machine to sound metal hand-guided cuts which are to be exposed or visible.

2.2.2 Assembly

Shop drawings shall provide the sequence of fabrication and assembly and

SECTION 05 59 13 Page 10 provide details for connecting the adjoining fabricated components in the shop. Assembly details shall identify the required order of assembly and details of witness points as described in these specifications.

2.2.3 Welded Connections

2.2.3.1 Welding Procedure

Prequalify welding procedures for structural steel as described in AWS D1.1/D1.1M, Subclause 3.1 or qualify by tests as prescribed in AWS D1.1/D1.1M, Clause 4. Properly documented evidence of compliance with all requirements of these specifications for previous qualification tests establish a welding procedure as prequalified. For welding procedures qualified by tests, the test welding and specimen testing will be witnessed and the test report document signed by the Contracting Officer. Approval of any welding procedure will not relieve 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.

a. Submit a complete schedule of welding procedures for each steel structure to be welded prior to commencing fabrication. Provide the schedule in conformance with the requirements specified in the provisions AWS D1.1/D1.1M, Clauses 2, 3, 4, 6, 7 and applicable portions of Clause 8.

b. Provide within the schedule detailed procedure specifications and tables or diagrams showing the procedures to be used for each required joint. Include in the welding procedures filler metal, preheat, interpass temperature and stress-relief heat treatment requirements.

Clearly identify each welding procedure as being prequalified or required to be qualified by tests.

c. Show types and locations of welds designated or in the specifications to receive nondestructive testing in the welding procedures.

2.2.3.2 Welder Performance Qualification of Welders and Welding Operators

Welding operators, welders, and tack welders shall be qualified and requalified if necessary for the particular type of work to be done.

Qualification shall be in accordance with 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. Copies of the Performance Qualification records shall be submitted to the Government Representative and approved before fabrication is commenced. Require the welder and welding operators to repeat the qualifying tests when, in the opinion of the Government Representative/Engineer, the work indicates a reasonable doubt as to proficiency. In such cases, the welder shall be recertified, as above, after successfully passing the retest; otherwise, he/she shall be disqualified until successfully passing a retest. The period of effectiveness for all welder and welding operator performance qualifications shall be in accordance with AWS D1.1/D1.1M. Keep the certification current for the duration of the contract. All expenses in

SECTION 05 59 13 Page 11 connection with qualification and requalification shall be borne by the Contractor.

2.2.3.3 Welding Process

Perform welding of structural steel by an electric arc welding process using a method which excludes the atmosphere from the molten metal and conforms to the applicable provisions of AWS D1.1/D1.1M. Minimize residual stresses, distortion and shrinkage from welding.

2.2.3.4 Welding Technique

2.2.3.4.1 Filler Metal

Provide the electrode, electrode-flux combination and grade of weld metal conforming to the appropriate AWS specification for the base metal and welding process being used or be as shown where a specific choice of AWS specification allowables is required. Include the AWS designation of the electrodes to be used in the schedule of welding procedures. Use only low hydrogen electrodes for manual shielded metal-arc welding regardless of the thickness of the steel. Use a controlled temperature storage oven at the job site as prescribed by AWS D1.1/D1.1M, Subclause 3.5 to maintain low moisture of low hydrogen electrodes.

2.2.3.4.2 Preheat and Interpass Temperature

Perform preheating as required by AWS D1.1/D1.1M, Subclause 3.5 or as otherwise specified except that the temperature of the base metal must be at least 70 degrees F. Slowly and uniformly preheat the weldments 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.

2.2.3.4.3 Stress-Relief Heat Treatment

Where stress relief heat treatment is specified or shown, perform in accordance with the requirements of AWS D1.1/D1.1M, Subclause 5.8 unless otherwise authorized or directed.

2.2.3.5 Workmanship

Perform welding workmanship in accordance with AWS D1.1/D1.1M, Clause 3 and other applicable requirements of these specifications.

2.2.3.5.1 Preparation of Base Metal

Prior to welding inspect surfaces to be welded to ensure compliance with AWS D1.1/D1.1M, Subclause 3.2.

2.2.3.5.2 Tack and Temporary Welds

Make temporary welds, required for fabrication and erection, under the controlled conditions prescribed for permanent work. Make temporary welds using low-hydrogen welding electrodes and by welders qualified for permanent work as specified in these specifications. Conduct preheating for temporary welds as required by AWS D1.1/D1.1M for permanent welds except that the minimum temperature must be 120 degrees F in any case. In making temporary welds, do not strike arcs in other than weld locations.

Remove each temporary weld and grind flush with adjacent surfaces after

SECTION 05 59 13 Page 12 serving its purpose.

2.2.3.5.3 Tack Welds

Subject tack welds that are to be incorporated into the permanent work to the same quality requirements as the permanent welds; clean and thoroughly fuse them with permanent welds. Perform preheating as specified above for temporary welds. Multiple-pass tack welds must have cascaded ends. Remove defective tack welds before permanent welding.

2.2.3.5.4 Weld Access Holes

Provide weld access holes as shown on the shop drawings. If the oversite of intersecting out-of-plane welds is encountered, the fabricator shall notify the Contracting Officer for the approval of weld access hole additions in such locations. Payment for the addition of weld access holes not shown on plans will be the Contractor's responsibility.

2.2.3.5.5 Weld Backing Removal

Unless otherwise indicated, remove all steel weld backing material from welded joints prior to testing. Identify on the shop drawings all weld backing material that cannot be removed.

2.2.3.5.6 Weld Backing Material Other Than Steel

All weld backing material, other than steel, shall be qualified by testing and shall be included in submitted PQR/WPS. Variation from approved weld backing material will not be permitted and will require the development and testing a new weld procedure which addresses the change in backing material.

2.2.4 Bolted Connections

All high strength connections shall be tightened to a tension not less than that given below for ASTM A325 Bolts. Tightening shall be done by turn-of-nut, direct tension indicator, calibrated wrench, or alternative design bolt methods.

5/8 inch 19 kips

3/4 inch 28 kips

7/8 inch 39 kips

1 inch 51 kips

1-1/8 inch 56 kips

1-1/4 inch 71 kips

1-3/8 inch 85 kips

1-1/2 inch 103 kips

All other connections shall be tightened to the snug-tight condition. The snug-tight condition is defined as the tightness attained by either a few

SECTION 05 59 13 Page 13 impacts of an impact wrench or the full effort of a worker with an ordinary spud wrench that brings the plies into firm contact. Perform snugging in a systematic manner starting at the most rigid part of the joint and working to the outside of the connection or the free edges. Use thin metal feeler gages, such as a machinists 6 inch metal rule, to ensure that gaps do not exist between the steel at the bolt holes. Install all bolts in a connection to a snug tight condition prior to pretensioning. Perform pretensioning in the same order as snug-tightening.

2.2.4.1 Bolts, Nuts, and Washers

Provide bolts, nuts and washers of the type specified or indicated. All nuts to be used with high strength bolts shall be ASTM A563. All nuts shall be equipped with washers. Where the use of high strength bolts is specified or indicated the materials, workmanship and installation shall conform to the applicable provisions of ASTM F3125/F3125M ASTM A325 and RCSC Specifications for Structural Joints Using ASTM A325 or ASTM A490 Bolts. Washers to be used with high strength bolts shall conform to

ASTM F436.

Bolts, nuts and washers shall be hot-dip galvanized or stainless steel ( ASTM A193/A193M, Gr. B8) as shown on the contract drawings or specified herein.

2.2.4.2 Bolt Holes

Bolt holes shall be accurately located, smooth, perpendicular to the member and cylindrical.

a. Holes for regular bolts shall be drilled or subdrilled and reamed in the shop and shall not be more than 1/16 inch larger than the diameter of the bolt.

b. Holes for high strength fitted bolts shall be match-reamed or drilled.

Remove burrs resulting from reaming. The threads of bolts shall be entirely outside of the holes. The body diameter of holes and bolts shall have tolerances as specified on the drawings.

c. All misdrilled holes shall be repaired as directed by the Engineer of Record. Repair of mislocated or misdrilled holes shall be submitted for Government approval.

2.2.5 Miscellaneous Provisions

2.2.5.1 Weldments

Portions of the structure include thick weldments where locked in thermal stresses may make final dimensions unstable. Sequence the work and thermally stress relieve subassemblies of thick weldments such that final machining achieves stable specified dimensions and tolerances.

2.2.5.2 Drain Holes

Locate drain holes as shown on the drawings, unless otherwise noted. Drill drain holes. Flame cutting of holes will not be permitted.

2.2.6 Shop Assembly

Perform fabrication and assembly in an indoor, climate controlled shop.

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Each item shall be closely checked to ensure that all necessary clearances have been provided and that binding does not occur in any moving part. All shop testing for assembly shall be witnessed by the Government Representative. Errors or defects disclosed shall be immediately remedied without cost to the Government.

2.2.7 Seals

Provide rubber seals as indicated in paragraph "rubber seals". The surfaces of finished splices shall be smooth and free of irregularities.

Bolt holes in the rubber seals shall be match-drilled with the seal support and clamping bars, as applicable; to insure proper fit and spacing between holes of the completed seal assembly. Seal support and clamping bars shall conform to the configurations shown on the drawings and shall be machine finished. The seals and blocks shall be installed after painting has been completed.

2.3 TESTS, INSPECTIONS, AND VERIFICATIONS

All tests and analyses shall be performed and certified at the Contractor's expense. Perform tests, inspections, and verifications conforming to the requirements of the particular sections of these specifications for the respective items of work unless otherwise specified or authorized. Conduct tests in the presence of the Contracting Officer if so required. Furnish specimens and samples for additional independent tests and analyses upon request by the Contracting Officer. Properly label specimens and samples and prepare for shipment.

2.3.1 Nondestructive Testing (NDT)

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, magnetic particle, 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 by the same test method that located the defect at the Contractor's expense.

2.3.2 Inspection of Structural Steel Welding

2.3.2.1 Visual Examination

All welds shall have visual examination (VT). clean and carefully examine 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, Clause 6, Subclause 6.9, Part C.

2.3.2.2 Nondestructive Examination

Perform the nondestructive examination of welds as specified or described on the drawings or as listed in the following paragraphs.

2.3.2.2.1 Testing Agency

The nondestructive testing of welds and the evaluation of tests as to the acceptability of the welds must be performed by a testing agency adequately equipped and competent to perform such services or by the Contractor using

SECTION 05 59 13 Page 15 suitable equipment and qualified personnel. In either case, written approval of the examination procedures is required and perform the examination tests in the presence of the Contracting Officer. The evaluation of tests are subject to the approval and all records become the property of the Government.

2.3.2.2.2 Examination Procedure

Conform to the following requirements.

2.3.2.2.3 Acceptability of Welds

Welds will 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.

2.3.2.2.4 Examination Procedures

Examination procedures shall conform to the following requirements:

2.3.2.2.4.1 Ultrasonic Testing (UT)

Make, evaluate and report ultrasonic testing of welds in conform to the requirements of AWS D1.1/D1.1M, Clause 6, Part C. Provide ultrasonic equipment capable of making a permanent record of the test indications.

Make a record of each weld tested.

2.3.2.2.4.2 Magnetic Particle Inspection (MT)

Conform magnetic particle inspection of welds to the applicable provisions of ASTM E709.

2.3.2.2.4.3 Dye Penetrant Inspection (PT)

Dye penetrant inspection(PT) of welds shall conform to the applicable provisions of ASTM E165/E165M.

2.3.3 Welds to be Subject to Nondestructive Examination

All welds (100 percent) of the air seal assemblies and the valve stem support assemblies / valve stem extensions shave have visual inspection (VT). In addition, 25 percent of all welds shall be randomly selected for Magnetic Particle Inspection (MT), Dye Penetrant Inspection (PT) or Ultrasonic Testing (UT). Submit the complete NDT reports for approval.

2.3.3.1 Structural Steel Members

Full Penetration Welds. Welds shall be inspected in conformance with AWS D1.1/D1.1M. Testing shall include a representative sample of welds and weld types from all welders and each of the processes each welder used.

Testing shall be spread throughout the project. Test 25 percent of all Full Penetration welds to UT, MT, or PT.

2.3.3.2 Structural Steel Member Fillet Welds and Partial Penetration Welds

Randomly select a minimum of 25 percent of all fillet welds and partial penetration welds for examination by magnetic particle and or dye penetrant testing procedures described previously. The random testing includes a representative sample of welds and weld types from all welders and each of

SECTION 05 59 13 Page 16 the processes each welder used. Spread the random testing throughout the project. Develop and submit a schedule for implementing the random testing for approval prior to fabrication.

2.3.4 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 an appropriate manner with joints of the proper type to develop the full strength of the members. Repaired joints shall be heated or 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 will be borne by the Government. If the coupons fail testing, repair costs as well as sampling costs, will be borne by the Contractor.

2.3.5 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. If welds are found to be defective, repair the defective work and bear the cost of the inspection.

2.3.6 Structural Steel Welding Repairs

Repair defective welds in the structural steel welding repairs in accordance with AWS D1.1/D1.1M, Subclause 3.7. Remove defective weld metal to sound metal by use of air carbon-arc or oxygen gouging. Do not use oxygen gouging on ASTM A514/A514M steel. Thoroughly clean surfaces before welding. Retest welds that have been repaired 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 will be borne by the Contractor. Submit welding repair plans for steel, prior to making repairs.

2.3.7 Control Dimensions

After fabrication of each structure, but prior to painting, record and submit on the "control dimensions" chart provided, the actual dimensions indicated on drawings. Control dimensions shall be verified prior to witness points defined under the schedule of witness points so that they may be verified during inspection and prior to either final assembly, painting, or installation of the structure. All control dimensions shall be verified and documented prior to shipping the structure.

PART 3 EXECUTION

3.1 INSTALLATION

3.1.1 Cleaning

All parts to be installed shall be thoroughly cleaned. Packing compounds, SECTION 05 59 13 Page 17 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. Non-Structural 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 marine grade antigalling compound.Contractor must supply a spare 40 oz.

supply of the anti galling compound for future use. Driving and drifting bolts or keys will not be permitted.

3.1.2 Alignment and Setting

Each machinery component or structural unit attached to structural fabricated according to this specification 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. Shims are to remain with the final installation where called for on the drawings. Where parts are press-fit, anti seize compound shall be applied to laying surfaces.

3.1.3 Field Installation

Field installation is not included in the contract. It shall be provided by others.

3.2 PROTECTION OF FINISHED WORK

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. Finished surfaces of ferrous metals to be in bolted contact shall be washed with an approved rust inhibitor and coated with an approved rust resisting compound for temporary protection during fabrication, shipping and storage periods. Finished surfaces of metals shall be painted as specified in specification SECTION 09 97 02:

PAINTING - HYDRAULIC STRUCTURES.

3.3 PAINTING

All surfaces of the structure shall be painted as specified in Section 09 97 02: PAINTING - HYDRAULIC STRUCTURES. All edges of plate shall be ground prior to coating. Grinding plate edges shall be accomplished before paint preparation in order to remove hardness as a result of flame cutting. All square edges and holes other than bolt holes shall be broken and ground to a 1/16 inch radius prior to painting.

Paint shall not be applied on nameplates, adjusting screws, corrosion resisting steel or other components whose operation, assembly, or disassembly would be affected by paint application.

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3.4 SHOP INSPECTION

The first air seal assembly and valve stem assembly to be fabricated and assembled for this contract shall be totally assembled in the shop as approved by the Technical Point of Contact (POC). Fabrication tolerances shall not exceed those shown on the contract drawings. Fabrication of the remaining air seal assemblies shall not be initiated until written approval is received from the Technical POC. Subsequent inspections on other air seal assemblies and valve stem assemblies by the Technical POC may also be performed. The Contractor shall give the Technical POC at least fourteen

(14) calendar days notice prior to inspection of the initial air seal assembly.

Unless otherwise noted, all air seal assemblies shall be inspected and approved by the Technical POC prior to delivery.

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