W912P521Q0036_TSpecs_35 20 15_Amnd0001 2021-08-18.pdf

Sector Gear Replacement Pickwick Lock W912P521Q0036 Amendment 0001 RTA Hardin County, Tennessee

SECTION TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

SECTION 35 20 15

SECTOR GEAR REPLACEMENT

PART 1 GENERAL

1.1 SCOPE

1.2 PERIOD OF PERFORMANCE

1.3 APPLICABLE DRAWINGS

1.4 REFERENCES

1.5 SUBMITTALS

1.6 QUALITY ASSURANCE

1.6.1 Acceptable Contractor

1.6.2 Contractor Qualifications

1.6.3 Quality Control

1.6.4 Reporting

1.7 DRAWINGS / INFORMATION TO BE FURNISHED BY THE CONTRACTOR

1.7.1 Drawings

1.7.2 Letter of Certification and Technical Data

1.7.3 Fabrication Assembly Procedure

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Structural Steel plate

2.1.2 Steel Forgings

2.1.3 Steel Castings

2.1.4 Bushings

2.1.5 Strut Pin

2.1.6 Turn Bolts

2.2 FABRICATION

2.2.1 General

2.2.2 Dimensional Tolerances for Structural Work

2.2.3 Structural Steel Fabrication

2.3 WELDING

2.3.1 Welding Procedures for Structural Steel

2.3.2 Welding of Steel Castings

2.3.3 Welding Process

2.3.4 Welding Technique

2.3.4.1 Filler Metal

2.3.4.2 Preheat and Interpass Temperature

2.3.4.3 Stress Relief Heat Treatment

2.3.5 Workmanship

2.3.5.1 Preparation of Base Metal

2.3.5.2 Temporary Welds

2.3.5.3 Tack Welds

2.3.6 Welder Qualifications

2.3.6.1 Welder, Welding Operator, and Tacker Qualification

2.3.6.1.1 Previous Qualifications

2.3.6.1.2 Certificates

2.3.6.1.3 Renewal of Qualification

2.3.6.2 Inspector Qualification

SECTION 35 20 15 Page 1

2.4 MACHINE WORK

2.4.1 General

2.4.2 Finished Surfaces

2.4.3 Unfinished Surfaces

2.4.4 Gear Teeth

2.5 SURFACE HARDENING OF GEAR TEETH

PART 3 EXECUTION

3.1 TESTS, INSPECTION AND VERIFICATION

3.1.1 Qualification Of Welders And Welding Operators

3.1.2 Material Tests

3.1.3 Nondestructive Testing

3.1.4 Inspection of Structural Steel Welding

3.1.4.1 Visual Examination

3.1.4.2 Nondestructive Examination

3.1.4.3 Test Coupons

3.1.4.4 Supplemental Examination

3.1.5 Structural Steel Welding Repairs

3.1.6 Inspection of Forgings

3.2 CLEANING AND PAINTING

3.2.1 Cleaning

3.2.2 Surfaces to be Painted

3.2.3 Painting System

3.3 COMPONENT WEIGHTS

3.4 SHOP ASSEMBLY AND INSPECTION

3.4.1 Shop Assembly

3.4.2 Shop Inspection

3.5 DELIVERY, STORAGE AND HANDLING

3.5.1 General

3.5.2 Protection of Finished Surfaces

3.5.3 Handling and Storage Instructions

3.5.4 Notification Prior to Shipping

3.5.5 Place of Delivery

-- End of Section Table of Contents --

SECTION 35 20 15 Page 2

SECTION 35 20 15

SECTOR GEAR REPLACEMENT

PART 1 GENERAL

1.1 SCOPE

The work shall consist of fabricating and delivering to Pickwick Lock one set of replacement components for the operating machinery of one Pickwick Miter Gate Sector Gear. The total number of replacement components to be provided shall be as specified herein and on the contract drawings:

a. Sector Gear: Required one (1), MK 9^R

b. Pinion Gear: Required one (1), MK 14

c. Gear Bushing: Required two (2), MK 12

d. Pinion Keys: Required two (2), MK 13

e. Trunnion Block: Required one (1), MK 22

f. Arm Bushings: Required two (2), MK 11

g. Strut Pin : Required one (1), MK 42

h. Turned Bolts w/ Nuts & LW: Required twenty (20), MK 16

i. Turned Bolts w/ Nuts & LW: Required twenty (2), MK 17

j. Turned Bolts w/ Nuts & LW: Required twenty (2), MK 18

k. Head screws, pipe plugs, dowels (MK 28, 29), grease fittings (MK 26), eyebolts (MK 30) and other miscellaneous items shown on drawing 64E250-3 shall also be provided by the Contractor. These items shall be shown on the shop drawings and product data shall be provide with shop drawings as applicable for approval.

The equipment listed above will be referred to collectively as sector gear equipment throughout these specifications. The installation of the replacement sector gear equipment at the site, including all field modifications necessary, and the preparation of the final as-built drawings will be performed by the Government.

1.2 PERIOD OF PERFORMANCE

The Period of Performance is 365 calendar days after the contract is awarded.

1.3 APPLICABLE DRAWINGS

a. Contract drawings: 64E250-3, 64E250-5.

All areas hashed on the drawings are NOT part of the project scope. All quantities shown on the drawings are incorrect, contractor should base all

SECTION 35 20 15 Page 3 work on quantities in Section 1.1 of the this package.

b. Installation drawing: 64E250-2. This drawing is supplied for reference only. The work shown shall be performed by the Government personnel.

c. Reference drawings and for information only drawings: All Drawings designated as such.

1.4 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 GEAR MANUFACTURERS ASSOCIATION (AGMA)

ANSI/AGMA 2009 (2001B; R 2008) Bevel Gear Classification, Tolerances, and Inspection Methods

AMERICAN IRON AND STEEL INSTITUTE (AISI)

AISI 4130 H Alloy Steel

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)

AMERICAN WELDING SOCIETY (AWS)

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

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

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B4.1 (1967; R 1994; R 2004; R 2009; R 2020)

Preferred Limits and Fits for Cylindrical Parts

ASME B46.1 (2020) 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 A354 (2017; E 2017; E 2018) Standard Specification for Quenched and Tempered Alloy Steel Bolts, Studs, and Other Externally Threaded Fasteners

ASTM A36/A36M (2019) Standard Specification for Carbon Structural Steel

SECTION 35 20 15 Page 4

ASTM A449 (2014; R 2020) Standard Specification for Hex Cap Screws, Bolts, and Studs, Steel, Heat Treated, 120/105/90 ksi Minimum Tensile Strength, General Use

ASTM A572/A572M (2018) Standard Specification for High-Strength Low-Alloy Columbium-Vanadium Structural Steel

ASTM A668/A668M (2020a) Standard Specification for Steel Forgings, Carbon and Alloy, for General Industrial Use

ASTM B22/B22M (2017) Standard Specification for Bronze Castings for Bridges and Turntables

ASTM E165 (2009) Standard Test Method for Liquid Penetrant Examination

ASTM E709 (2015) Standard Guide for Magnetic Particle Examination

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC 7/NACE No.4 (2007) Brush-Off Blast Cleaning

SSPC SP 2 (2018) Hand Tool Cleaning

SSPC SP 3 (2018) Power Tool Cleaning

1.5 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. The following shall be submitted:

SD-01 Preconstruction Submittals

Contractor Qualifications; G

Submit Contractor qualifications with bid. Copy required.

Quality Control Plan; G

Submit quality control plan 14 calendar days after Award of Contract.

SD-02 Shop Drawings

Shop Drawings; G

SD-03 Product Data

Painting; G

SD-05 Design Data

SECTION 35 20 15 Page 5

Fabrication Assembly Procedure ; G

Submit Fabrication Assembly Procedure prior to commencement of fabrication.

SD-06 Test Reports

Component Weights;

Submit component weights 7 days prior to Government inspection of Fabrication at Contractor's Facility.

Hardness Test Report; G

Ndt Report; G, ECD-E

SD-07 Certificates

Qualification of Welders and Welding Operators; G

Submit welder certification prior to commencement of fabrication.

Letter of Certification and Technical Data; G

Submit letters of certification (materials, paint and filler material) one week prior to Government inspection of Fabrication at Contractor's Facility.

Record of Nondestructive Test and Examination Procedures ; G

SD-09 Manufacturer's Field Reports

Shop Inspection Procedure; G

Submit shop inspection procedure 14 days prior to shop inspection.

Shop Inspection Report; G

Handling and storage Instructions; G

Submit handling and storage instructions 14 days prior to scheduled delivery date.

SD-11 Closeout Submittals

Delivery of Equipment; G

Delivery equipment within 180 days after notice to proceed.

Record Drawings; G

Provide as-built drawings 15 days after the delivery of equipment.

SECTION 35 20 15 Page 6

1.6 QUALITY ASSURANCE

1.6.1 Acceptable Contractor

The Contractor for the fabrication of the specified equipment shall be one who is in the business of fabricating precision gearing equipment. The Contractor shall have no less than 10 years experience in the fabrication of similar equipment. The manufacturer shall be subject to the government's approval.

1.6.2 Contractor Qualifications

A statement identifying the name of the contractor containing evidence that the contractor meets the experience requirements of paragraph "Acceptable Contractor".

1.6.3 Quality Control

The Contractor shall establish and maintain a quality control system to assure compliance with the requirements of these specifications and shall maintain records of quality control of all operations covered by these specifications. The contractor shall submit for review the quality control plan for the work to be performed. See paragraph Tests, Inspection and Verification for details.

a. The Contractor s facilities shall be open, during normal business hours, to the Contracting Officer or his authorized representative for the purpose of inspection of work, completed and in progress, on this contract. The aforementioned quality control records shall be available for inspection. The Government shall be notified at least 10 days prior to painting of gears to enable shop inspection of the gears by Government Inspectors at Contractor s facility.

b. The contractor shall submit a quality control plan for the work to be performed.

1.6.4 Reporting

Three copies of the records and tests, as well as the records of corrective action taken, shall be furnished to the government when requested.

1.7 DRAWINGS / INFORMATION TO BE FURNISHED BY THE CONTRACTOR

1.7.1 Drawings

The contractor shall be required to make a site visit prior to submitting shop drawings for technical approval in order to field verify all dimensional and connectivity information.

Shop drawings shall include fabrication and assembly details, type, grade, and class of materials, as appropriate. Elements of fabricated items inadvertently omitted on contract drawings shall be detailed by the fabricator and indicated on the shop drawings.

a. Shop drawings in PDF and CAD formation shall be provided for approval. Decisions on these drawings, either approval or disapproval, will be given by the Contracting Officer by letter or email. Within 15 calendar days after receipt, the Contracting Officer

SECTION 35 20 15 Page 7 will return one copy to the Contractor marked Approved , Approved Except as Noted , or Returned for Correction . The notations Approved and Approved Except as Noted authorize the Contractor to proceed with the fabrication of the equipment covered by such drawings, subject to the corrections, if any, indicated thereon or described in the letter of transmittal. When drawings have been Returned for Correction , the Contractor shall make the necessary revisions on the drawings and shall submit prints for approval in the same routine as before. Every revision made during the life of the contract shall be shown by the number, date, and subject in a revision block and a notation shall be made in the drawing margin to permit rapid location of the revision. The time consumed by the Contractor in submitting and obtaining approval of shop drawings shall be included in the time allowed for completion of the contract.

b. Record drawings that detail the fabricated equipment shall be submitted at the completion of the project.

c. contractor shall submit shop drawings and as-built drawings in PDF format and .dgn formats. Other format may also be acceptable.

1.7.2 Letter of Certification and Technical Data

Letters of certification shall be provided for steel, filler metal and paint. Technical data shall be provided for filler metal and paint.

Certified test reports for all required materials shall show that materials comply with applicable specifications. These reports shall note specific standards followed in the performance of tests. A certified letter documenting the final tooth surface hardness including the testing method shall be supplied. See paragraph "Surface Hardening of Gear Teeth" for details. Certification and Technical Data shall be submitted for approval.

1.7.3 Fabrication Assembly Procedure

A Fabrication Assembly Procedure shall be prepared by the Contractor and submitted to the Contracting Officer for approval. The procedure shall detail the order in which components of the sector gear will be fabricated and assembled, the welding procedures to be used for all welds and the methods the Contractor will employ to control distortion of the weldment.

It shall include all preparatory steps, post-weld treatments, joint dimensions and tolerances. All welding procedures approved for use shall receive a Government stamp identifying them as approved. Only welding procedures bearing a Government approval stamp shall be allowed for use during fabrication. Approval of any welding procedure does not relieve the Contractor of the responsibility for producing a finished structure meeting all requirements of these specifications. The Contractor may be directed or authorized to make any changes in previously approved welding procedures that are deemed necessary or desirable by the COR.

PART 2 PRODUCTS

2.1 MATERIALS

The Sector Gear MK 9R can be made from cast steel as shown on the contract drawings or can be fabricated carbon steel, forged steel, and other materials as shown on the FOR INFORMATION ONLY DRAWINGS of the Kentucky Lock Sector Gear Replacement. Requirements for all are listed below.

SECTION 35 20 15 Page 8

2.1.1 Structural Steel plate

Structural steel for the spokes of the Sector Gear MK 9R shall conform to ASTM A36/A36M. Keeper plate shall conform to ASTM A572/A572M .

2.1.2 Steel Forgings

MK 9R (sector gear rim), MK 9R (Sector gear hub), and MK 14 (pinion gear): AISI 4130 H Alloy steel. See paragraph "SURFACE HARDENING OF GEAR TEETH" for requirement of heat treatment.

MK 22 (Trunnion Block): ASTM A668/A668M , Class E

2.1.3 Steel Castings

If the Contractor selects to use steel casting for the sector gear (MK 9R), it shall conform to ASTM A148/A148M Grade 90-60 Cast steel.

2.1.4 Bushings

Bushing, MK 11 and MK 12, material shall conform to ASTM B22/B22M, UNS86300 (110 ksi tensile strength) , manganese bronze.

2.1.5 Strut Pin

The Strut Pin MK 42 shall conform to ASTM A668/A668M , Gr. H.

2.1.6 Turn Bolts

Turn bolts MK 16, MK 17, and MK 18 ( ASTM A354, Gr. BC) shall be galvanized. Bolts shall be furnished with galvanized nuts and washers.

Galvanized cap screw shall conform to ASTM A449. Provide galvanized lock washer with cap screw.

2.2 FABRICATION

2.2.1 General

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 on the drawings. 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.

2.2.2 Dimensional Tolerances for Structural Work

Dimensions shall be measured by an approved calibrated steel tape of approximately the same temperature as the material being measured. Where

SECTION 35 20 15 Page 9 tolerances are not specified in other sections of these specifications or shown, an allowable variation of 1/32 inch is permissible in the overall length of component members with both ends milled and component members without milled ends shall not deviate from the dimensions shown by not more than 1/16 inch.

2.2.3 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 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.

2.3 WELDING

2.3.1 Welding Procedures for Structural Steel

Welding procedures for structural steel shall be pre-qualified as described in AWS D1.1/D1.1M or shall be qualified by tests as prescribed in AWS D1.1/D1.1M . Properly documented evidence of compliance with all requirements of these specifications for previous qualification tests shall establish a welding procedure as pre-qualified. For welding procedures qualified by tests, the test welding and specimen testing must be witnessed and the test report document signed by a representative of 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 pre-qualified or required to be qualified by tests. Welding procedures must show types and locations of welds designated on the drawings or in the specifications to receive nondestructive examination.

2.3.2 Welding of Steel Castings

Remove unsound material from the surfaces of steel castings, to be incorporated into welded connections, by chipping, machining, air-arc gouging or grinding. Do not weld major connections designed for transfer of stresses if the temperature of the casting is lower than 100 degrees F.

Preheat castings containing over 0.35 percent carbon or over 0.75 percent manganese to a temperature not to exceed 450 degrees F and conduct welding while the castings are maintained at a temperature above 350 degrees F.

Welding is not permitted on castings containing carbon in excess of 0.45 percent except on written authorization. Castings requiring welding repairs after the first annealing and castings involving welding fabrication must be stress-relieved annealed prior to receiving final machining unless otherwise permitted.

SECTION 35 20 15 Page 10

2.3.3 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.

2.3.4 Welding Technique

2.3.4.1 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 on the drawings 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.

2.3.4.2 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.

2.3.4.3 Stress Relief Heat Treatment

Where stress relief heat treatment is specified or shown on the drawings it shall be in accordance with the requirements of AWS D1.1/D1.1M unless otherwise authorized or directed by the Contracting Officer.

2.3.5 Workmanship

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

2.3.5.1 Preparation of Base Metal

Prior to welding the Contractor shall inspect surfaces to be welded to assure compliance with AWS D1.1/D1.1M .

2.3.5.2 Temporary Welds

Temporary welds required for fabrication and erection shall be made under the controlled conditions prescribed herein 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.

SECTION 35 20 15 Page 11

2.3.5.3 Tack Welds

Tack 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.

2.3.6 Welder Qualifications

2.3.6.1 Welder, Welding Operator, and Tacker Qualification

Each welder, welding operator, and tacker assigned to work on this contract shall be qualified in accordance with the applicable requirements of AWS D1.1 and as specified in this section. Welders, welding operators, and tackers who make acceptable procedure qualification test welds will be considered qualified for the welding procedure used. In addition to the requirements listed in AWS D1.1/D1.1M all welding procedures and base metal shall have minimum requirements of a charpy V-notch impact test with a load of 25 ft-lbs at 70 degrees Fahrenheit.

2.3.6.1.1 Previous Qualifications

a. Copies of the welding procedure specifications, the procedure qualification test records, and the welder, welding operator, and tacker qualification test records are submitted and approved in accordance with the specified requirements for detail drawings.

b. Testing was performed by an approved testing laboratory, technical consultant, or the Contractor's approved quality control organization.

c. The previously qualified welding procedure conforms to the requirements of this specification and is applicable to welding conditions encountered under this contract.

d. The welder, welding operator, and tacker qualification tests conform to the requirements of this specification and are applicable to welding conditions encountered under this contract.

2.3.6.1.2 Certificates

Before assigning any welder, welding operator, or tacker to work under this contract, the Contractor shall 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 on file, and 3 copies shall be furnished. The certification shall be kept current for the duration of the contract.

2.3.6.1.3 Renewal of Qualification

Requalification of a welder or welding operator shall be required under any of the following conditions:

SECTION 35 20 15 Page 12

a. It has been more than 12 months since the welder or welding operator has used the specific welding process for which he is qualified.

b. There is specific reason to question the welder or welding operator's ability to make welds that meet the requirements of these specifications.

c. The welder or welding operator was qualified by an employer other than those firms performing work under this contract, and a qualification test has not been taken within the past 12 months.

Records showing periods of employment, name of employer where welder, or welding operator, was last employed, and the process for which qualified shall be submitted as evidence of conformance.

d. A tacker who passes the qualification test shall be considered eligible to perform tack welding indefinitely in the positions and with the processes for which he is qualified, unless there is some specific reason to question the tacker's ability. In such a case, the tacker shall be required to pass the prescribed tack welding test.

2.3.6.2 Inspector Qualification

All shop and field welding inspectors shall be qualified in accordance with the requirements of AWS QC1 and nondestructive testing personnel shall be qualified in accordance with the requirements of ANSI/ASNT CP-189 for Levels I or II in the applicable nondestructive testing method. The inspector may be supported by assistant welding inspectors who are not qualified to ASNT 01, and assistant inspectors may perform specific inspection functions under the direct supervision of the qualified inspector.

2.4 MACHINE WORK

2.4.1 General

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 (except for the surface of the gear teeth which shall be per AGMA). 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 bolts shall be accurately located.

2.4.2 Finished Surfaces

Surface finishes indicated or specified herein 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

SECTION 35 20 15 Page 13 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.

2.4.3 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.

2.4.4 Gear Teeth

Gears teeth shall have machine cut teeth as specified per the contract drawings and the AGMA standards. Gear teeth tolerances for both the sector gear and pinion gear shall be shall be per ANSI/AGMA 2009 , corresponding to Quality Number 6. The contractor shall specify a suitable tooth thickness tolerance per AGMA on the shop drawings.

2.5 SURFACE HARDENING OF GEAR TEETH

Surface hardening shall be performed on the gear teeth of the sector gear and pinion gear over the entire profile of the tooth. The contractor shall use an induction hardening process as approved by the Contracting Officer, to obtain the hardness range specified on the drawings. Hardness for pinion's teeth shall be 20-30 BHN greater than hardness of the Sector Gear's teeth. Sector Gear's teeth shall be 480-520 BHN. Contractor shall submit the hardness test report to show the hardness of gear teeth and pinion teeth. The requirements for hardening are as follows:

a. Surface to 1/8 in. beneath surface - Hardness range as specified on contract drawings.

b. 1/8 in. to 1/4 in. - Hardness within 50 points Brinell of the minimum required for the surface.

Surface hardening shall be performed after final machining of the teeth.

The procedure for surface hardening shall prevent distortion of the teeth and damage to the base metal. Flame hardening will not be approved by the Government before or after the contract is awarded.

PART 3 EXECUTION

3.1 TESTS, INSPECTION AND VERIFICATION

3.1.1 Qualification Of Welders And Welding Operators

Submit Qualification of Welders and Welding Operators for approval.

SECTION 35 20 15 Page 14

Qualification submittal shall be in accordance with AWS D1.1/D1.1M .

Certify that the qualification of welders and welding operators and tack welders who will perform structural steel welding have been qualified for the particular type of work to be done in accordance with the requirements of AWS D1.1/D1.1M prior to commencing fabrication. Submit the qualifications on Form N-4, Annex N of AWS D1.1/D1.1M , or equal. See paragraph "WELDING" for details.

3.1.2 Material Tests

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 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.

3.1.3 Nondestructive Testing

The contractor must perform one form of NDT testing on 100% of the welds independent of visual inspection. Thesemethods may include ultrasonic, magnaflux, dye penetrant, x ray, gamma ray or any other test that will thoroughly investigate the part in question. Any defects will be cause for rejection and rejected parts shall be replaced and tested at the Contractor's expense. Contractor shall submit the results of the NDT Report for approval

3.1.4 Inspection of Structural Steel Welding

100% of all welds will be visually inspected in accordance with AWS D1.1/D1.1M . The Contractor shall maintain an approved inspection system and perform required inspections in accordance with the contractor's. 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.

3.1.4.1 Visual Examination

All completed welds shall be cleaned and carefully examined 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 .

3.1.4.2 Nondestructive Examination

Contractor shall provide the record of nondestructive test and examination procedures for approval.

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

SECTION 35 20 15 Page 15

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. 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

(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 E709.

(4) Dye Penetrant Inspection: Dye penetrant inspection of welds shall conform to the applicable provisions of ASTM E165.

c. Acceptability of Welds: Welds shall be unacceptable if shown to have defects prohibited by AWS D1.1/D1.1M , Subsection 9.25 or possess any degree of incomplete fusion, inadequate penetration or undercutting.

d. The Contractor shall maintain documentation of all visual and nondestructive weld testing. The documentation shall show that applicable sections of the specifications are met. All radiographs, including those showing unacceptable quality prior to and after repair shall be included to document radiographic weld inspection.

Ultrasonic equipment qualification and weld inspection forms that document ultrasonic weld inspection shall be included.

e. Welds to be Subject to Nondestructive Examination: Welds subject to non-destructive testing shall be as shown on contract drawings.

3.1.4.3 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 if the evidence shows that the weld was sound, SECTION 35 20 15 Page 16 otherwise the expense shall be born by the contractor.

3.1.4.4 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 supplemental nondestructive examinations before final acceptance. The cost of such inspection will be borne by the Government.

3.1.5 Structural Steel Welding Repairs

Defective welds 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.

3.1.6 Inspection of Forgings

Forgings including Pinion, Sector Gear Rim and Sector Gear Hub shall be given ultrasonic examination with liberal overlap and other applicable non destructive tests, to determine that they are sound. The structure of forgings shall be homogeneous and free from excessive non-metalic inclusions. An excessive concentration of impurities or separation of alloying elements at critical points in a forging shall be cause for its rejection.

3.2 CLEANING AND PAINTING

3.2.1 Cleaning

Remove all loose rust, dirt, moisture, grease or other contaminants from surface. Power-tool clean in accordance with SSPC SP 3 or hand-tool clean in accordance with SSPC SP 2 . For more severe environments, dry abrasive blast in accordance with SSPC 7/NACE No.4 . Water blasting is also acceptable.

3.2.2 Surfaces to be Painted

All exterior surfaces shall be painted except for machined mechanical surfaces including gear teeth and sector arm bearing surfaces. Painting shall not be performed prior to inspection of the equipment by the Government unless waived. Machined-finished surfaces of metals which are exposed after installation shall also be painted in the shop by the contractor, except components whose operation, assembly, or disassembly would be affected by paint application. These surfaces shall be adequately protected during surface preparation and painting of the surfaces to be painted. Sector pin, turned bolts, and bronze bushings shall not be painted.

All finished surfaces shall be protected by suitable means. All unpainted machine-finished surfaces shall be protected by Houghton-Vaughan Co.'s "Rust Veto No. 342" for shipping and storage protection.

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3.2.3 Painting System

After cleaning, all surfaces shall be painted before formation of moisture on or contamination of the surfaces. Three (3) coats of CARBOLINE 890 with battleship gray color or approved equal shall be applied to the sector gear's exterior surfaces. Paint shall have an average film thickness of a minimum of 24 mils for the complete system. Contractor shall submit the painting product data and color for approval. The Contractor shall provide a small quantity (2 gallons) of paint to repaint any areas where the finish is damaged during transportation of the machinery. Coated surfaces damaged shall be repaired by the contractor without additional cost to the Government.

3.3 COMPONENT WEIGHTS

The Contractor shall weigh and record the weights of the Sector Gear, Pinion Gear, and Sector Pin. This information shall be provided to the Contracting Officer.

3.4 SHOP ASSEMBLY AND INSPECTION

3.4.1 Shop Assembly

The sector gear and bushings shall be assembled in the shop and final machined in assembly to the tolerances specified on the drawing.

3.4.2 Shop Inspection

A shop inspection procedure shall be prepared by the Contractor and submitted to the Contracting Officer for approval. Shop inspection of all equipment to be furnished shall be performed in the presence of the Contracting Officer or his representative in accordance with a procedure to be prepared by the Contractor and approved by the Contracting Officer.

This procedure shall include measurement of all critical dimensions including pitch, gear teeth thickness and pin and bushing diameters and finishes of critical surfaces. The Government shall be notified at least 14 days prior to packaging of the sector gear to enable shop inspection of the sector gear by Government Inspectors at Contractor's facility. The contractor shall submit shop inspection report for approval.

3.5 DELIVERY, STORAGE AND HANDLING

3.5.1 General

The furnished equipment shall be shipped to Pickwick Lock by the Contractor. The equipment shall be packed in a manner acceptable to preserve the condition of the equipment as it left the contractors shop.

The packaging shall clearly identify the contents of the package. Loose items such as bolts and screws shall be packaged together in a single package. Transportation charges shall be paid by the contractor.

3.5.2 Protection of Finished Surfaces

Finished unpainted surfaces on the sector gears, pinion gears, pins, and bushings, shall be suitably protected for shipment to prevent corrosion and damage during shipment and storage at the site.

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3.5.3 Handling and Storage Instructions

Handling and Storage Instructions shall be provided by the Contractor for the specified equipment to be provided. The Instructions shall include:

a. Identification of parts requiring special outdoor, indoor or temperature controlled storage.

b. Space Requirements for outdoor, indoor or temperature controlled storage.

c. The procedures to be observed in unloading, placing, stacking and blocking of the equipment.

d. In-storage inspection and care, and maximum recommended storage periods for items stored outdoors.

e. Application of protective coatings, lubrication, etc.

f. Cleaning of protective coatings and or corrosion prior to installation.

g. All components shall be wrapped with moisture resistant paper and packed in wooden boxes. These boxes shall be of sufficient strength so they can be rigged for and handled by a mobile crane and/or forklift.

3.5.4 Notification Prior to Shipping

The contractor shall make arrangements for delivery of equipment with the contact listed below for Pickwick Lock not less than fourteen (14) working days prior to delivery of the sector gear equipment.

3.5.5 Place of Delivery

Pickwick Lock POC: Randall King, Lock Master ADDRESS: 850 Carolina Lane

Counce, TN 38326 Phone: 731-925-2334 Phone Alt: 731-925-4564

Delivery shall be made between the hours of 8:00 a.m. and 3:00 p.m. local time at place of delivery, Monday through Thursday, except Federal holidays. Contractor is responsible for all cost to deliver the sector gear equipment to the project site. Government personnel and equipment will unload the materials at no cost to the Contractor.

-- End of Section --

SECTION 35 20 15 Page 19

2.3.6.2 Inspector Qualification

2.5 SURFACE HARDENING OF GEAR TEETH