W912P521Q0049 0001 Technical Specifications Amended.pdf

Barkley Lock Spare Hydraulic Cylinder Barkley Lock and Dam W912P521Q0049 Amendment 0001 RTA Kuttawa Kentucky

PROJECT TABLE OF CONTENTS

DI VI SI ON 01 - GENERAL REQUI REMENTS

01 20 00 PRICE AND PAYMENT PROCEDURES

01 33 00 SUBMITTAL PROCEDURES

01 35 50 PROJECT SITE SECURITY AND AT/OPSEC PROCEDURES

01 42 00 SOURCES FOR REFERENCE PUBLICATIONS

01 78 00 CLOSEOUT SUBMITTALS

DI VI SI ON 05 - METALS

05 50 14 STRUCTURAL METAL FABRICATIONS

DI VI SI ON 09 - FI NI SHES

09 97 02 PAINTING: HYDRAULIC STRUCTURES

DI VI SI ON 35 - WATERWAY AND MARI NE CONSTRUCTI ON

35 01 41 LOCK OPERATING MACHINERY

-- End of Project Table of Contents --

PROJECT TABLE OF CONTENTS Page 1

THIS PAGE INTENTIONALLY LEFT BLANK

PROJECT TABLE OF CONTENTS Page 2

SECTION TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

SECTION 35 01 41

LOCK OPERATING MACHINERY

PART 1 GENERAL

1.1 SCOPE

1.2 REFERENCES

1.3 RELATED WORK SPECIFIED ELSEWHERE

1.4 SUBMITTALS

1.5 QUALITY CONTROL

1.6 LOCK OPERATING MACHINERY-OPERATION AND MAINTENANCE INSTRUCTIONS

1.7 WARRANTY

PART 2 PRODUCTS

2.1 MITER GATE OPERATING MACHINERY

2.1.1 Operating Assemblies

2.1.2 Annealing

2.2 HYDRAULIC CYLINDER

2.2.1 General

2.2.2 Miter Gate Operating Machinery Cylinders and Rods

2.3 PINS AND BUSHINGS

PART 3 EXECUTION

3.1 GENERAL

3.2 SHOP ASSEMBLY

3.3 TESTS

3.3.1 Shop Assembly and Tests

3.3.1.1 General

3.3.1.2 Miter Gate Cylinder Tests

3.3.1.3 Common Tests for All Hydraulic Cylinders

3.4 SHIPPING OF CYLINDERS

3.5 PAINTING

-- End of Section Table of Contents --

SECTION 35 01 41 Page 1

THIS PAGE INTENTIONALLY LEFT BLANK

SECTION 35 01 41 Page 2

SECTION 35 01 41

LOCK OPERATING MACHINERY

PART 1 GENERAL

1.1 SCOPE

The work covered by this section consists of furnishing, and delivering item(s) listed below as well as additional information on the drawings or specified herein. Consideration may be given for no cost variations submitted for approval where practical and suitable with regard to substitution of machinery components called for on drawings. The following listed piece(s) of equipment is to be furnished, and delivered:

a. One (1) Fully assembled Miter Gate Hydraulic Cylinder and Piston Rod with all parts being accounted for in Section 05 50 14 STRUCTURAL METAL FABRICATIONS and contract drawings.

1.2 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by basic designation only.

AMERICAN WELDING SOCIETY (AWS)

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

ASTM INTERNATIONAL (ASTM)

ASTM A564/A564M (2019) Standard Specification for Hot-Rolled and Cold-Finished Age-Hardening Stainless Steel Bars and Shapes

ASTM A285/ A285M ( 2017) St andar d Speci f i cat i on f or Pr essur e Vessel Pl at es, Car bon St eel , Low- and I nt er medi at e- Tensi l e St r engt h

1.3 RELATED WORK SPECIFIED ELSEWHERE

Submittals shall be process according to Section 01 33 00 SUBMITTAL PROCEDURES. The provisions of Section 05 50 14 STRUCTURAL METAL FABRICATIONS shall be rigidly adhered to in performing the work under this section, inspection and testing of materials, patterns and workmanship, as well as all material requirements. All materials shall be of the classification and grade shown on the drawings and contract specifications or as approved by the Contracting Officer.

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:

SECTION 35 01 41 Page 3

SD-02 Shop Drawings

Miter Gate Hydraulic Cylinder And Rod; G, ECD-E

SD-05 Design Data

Alignment Procedures; G, ECD-E

SD-06 Test Reports

Quality Control; G, ECD-E

Common Tests For All Hydraulic Cylinders; G

Miter Gate Cylinder Tests; G, ECD-E

Shop Assembly And Tests; G, ECD-E

Submit test procedure for approval.

SD-08 Manufacturer's Instructions

SD-10 Operation and Maintenance Data

Lock Operating Machinery-Operation And Maintenance Instructions;

G, ECD-E

SD-11 Closeout Submittals

Delivery Of Equipment; G, ECD-E

1.5 QUALITY CONTROL

The Contractor shall establish and maintain quality control for operations under this section to assure compliance with contract requirements and maintain records of his quality control for all materials, fabricated parts, equipment, and fabrication operations. In addition, the Contractor shall establish and maintain surveillance for quality control over his subcontractors, suppliers, or manufacturers. The Contractor's quality control shall include a minimum of three (3) shop inspections during manufacture of the machinery. Quality control shall include but not be limited to the following:

a. Component dimensions, certified material test reports and workmanship

b. Manufacture, and transportation, complete

c. Lubrication

d. Shop assembly and tests

e. Damage and defects

A copy of these records and Contractor tests, as well as, the records of corrective action taken, shall be furnished the Government as specified in Section 01 33 00 SUBMITTAL PROCEDURES.

SECTION 35 01 41 Page 4

1.6 LOCK OPERATING MACHINERY-OPERATION AND MAINTENANCE INSTRUCTIONS

Unless otherwise noted, drawings shall be in PDF and CAD (.dgn and Inventor or others). All drawings shall be to scale. The instructions shall include, but not be limited to, the following:

(1) Individual assembly drawing of the Miter Gate Machinery Hydraulic Cylinder and Rod. Drawing shall identify every part or subassembly in the machine. The drawing shall include sufficient views, sections, details and notes to illustrate the assembly. Recommended torques on fasteners shall be included.

(2) Detailed drawings of subassembly of cylinder, mountings and others parts. Each part on the drawings shall be identified. Cylinder drawings shall show all dimensions and details of both the internal and external fabrication

(3) Maintenance instructions for each piece of equipment, including lubrication instructions and inspections for wear.

(4) Manufacturer's literature, cuts, and descriptive data of manufactured items in the machinery.

(5) Parts lists and recommended spare parts including names, addresses and telephone numbers for sources of parts.

Submit both shop drawings and calculations at the same time for approval.

See Paragraph "hydraulic cylinder" for design requirements.

1.7 WARRANTY

All equipment shall be guaranteed for a period of 2 years from the date of acceptance. Replacement parts shall be guaranteed for 2 years from the date of replacement. Warranty shall be against defective materials, design and workmanship. In cases where the equipment manufacturer's advertised minimum guarantee is in excess of 2 years, it shall remain in force for its full period. Upon receipt of notice from the Government of failure of any of the parts during the warranty period, new replacement parts shall be furnished and installed promptly at no additional cost to the Government. See additional warranty requirements in Section 01 78 00 CLOSEOUT SUBMITTALS, paragraph WARRANTY MANAGEMENT.

PART 2 PRODUCTS

2.1 MITER GATE OPERATING MACHINERY

2.1.1 Operating Assemblies

The Miter Gate Hydraulic Cylinder and Rod shall be fabricated of the materials called for and as detailed on the drawings and contract specifications. Materials, workmanship, inspection and painting shall conform to the requirements of the applicable sections of these specifications. When there is a discrepancy in material shown on the contract drawings and contract specifications, Contractor shall select the materials from the contract specifications.

Submit both shop drawings and calculations at the same time for approval.

See Paragraph "hydraulic cylinder" for design requirements.

SECTION 35 01 41 Page 5

2.1.2 Annealing

All weldments, castings, and forgings, before being machined, shall be stress relieved by heat treatment in accordance with AWS D1.1/D1.1M .

2.2 HYDRAULIC CYLINDER

2.2.1 General

The hydraulic cylinder shall be provided for operation of the miter gate operating machinery. All cylinders shall be double acting. The miter gate machinery shall be heavy duty mill type cylinders with bolting flanges rigidly welded on the cylinder tube. Dimensions and details shall be as shown on the drawings. All hydraulic cylinders shall be fabricated to withstand a maximum operating pressure of 3,000 psi. Material for the mill type cylinders shall be a high strength carbon or alloy steel. Cylinder tubes, which have been welded, shall be stress relief heat-treated. All welds shall be radiographed, including those on the trunnion and end mounts. Materials for the piston rod shall be as hereinafter specified.

Piston rod seals shall be of the split ring type. Ice scrapers shall also be split and retained with a split, bolted retainer to facilitate replacement without removal of the rod end clevis. Rings, bearings, packing, packing rings, retaining rings, seals, wiper-scrapers, wear bands, etc., shall be fabricated from the finest selected quality materials as recommended by the Manufacturer to provide zero leakage. The cylinder assembly shall have a rod end head and a blind end cap fastened to the cylinder by bolted connection. Ports shall be drilled, tapped and surfaced to receive SAE Code 61 flanges in the positions shown on the drawings. Manifold and pipe supports, as shown, shall be an integral part of the miter gate machinery cylinders and culvert valve machinery cylinders. Both ends of all the cylinders shall have convenient bleed ports. Each cylinder port shall be tapped to receive the 7/16-20-SAE bleed valves. Diagnostic connectors rated at least 4500 psi and consisting of a steel body with internal ball check and spring, male SAE o-ring connection and protective cap shall be provided as bleed valves and shall be equal to Parker Fluid Connector Company's Part No. PD 341. Diagnostic connectors shall be compatible with the diagnostic testing assemblies specified hereinafter. Any variance from the cylinders shown on the drawings or specified herein is subject to the approval of the Contracting Officer.

2.2.2 Miter Gate Operating Machinery Cylinders and Rods

The cylinders shall have a bore, rod diameter and a total stroke as shown on the drawings. Trunnions shall be rigidly welded on the cylinder tube.

The contractor is not responsible for mounting the hydraulic cylinder..

The Cyl i nder , MK. 22/ 2- 3, wi l l be made of ASTM A285/ A285M Cl ass C wi t h a t ensi l e st r engt h of 75 ksi . The piston rod shall be made of stainless steel with chrome plating. For the stainless steel piston rod , Mk. 28/ 2A- 1, with chrome plating, the stainless steel shall conform to ASTM A564/A564M Type XM- 25 wi t h a t ensi l e st r engt h of 125 ksi . It shall be heat treated to a condition of H-1150 before final machining. The final rod surface after chrome plating shall have a roughness height of not more than 8 microinch

RMS.

2.3 PINS AND BUSHINGS

All bushings shall be accurately machined to the tolerance shown on the

SECTION 35 01 41 Page 6 drawings. Where bushings have press fits into female parts, they shall be finished after assembly to the tolerances shown. All pins shall be accurately machined to the tolerances shown on the drawings.

PART 3 EXECUTION

3.1 GENERAL

All machinery and equipment shall be carefully assembled in correct relation and alignment to the connected mechanical and structural parts of the lock. Prior to assembly, the contractor shall submit for approval alignment procedures that shall identify critical machinery components requiring alignment, shall indicate the equipment used for alignment with respective accuracies, and shall provide a sequence by which the machinery shall be aligned. The contractor is not responsible for installing the Miter Gate Cylinder and Rod Assembly on Barkley Lock. The Contractor will be responsible for shipping the Miter Gate Cylinder and Rod assembly to Barkley Lock.

3.2 SHOP ASSEMBLY

All lock operating machinery shall be shop assembled in the presence of the Government inspector, so far as practicable, before shipment to the site to ensure that all parts fit properly and will assemble correctly in the field.

3.3 TESTS

3.3.1 Shop Assembly and Tests

3.3.1.1 General

The hydraulic cylinder manufacturer shall provide rigid inspection and testing of the cylinder. Test procedures shall be submitted for approval at least sixty (60) days before testing begins. Shop assembly and testing shall be done in the presence of the Contracting Officer's representative unless waived in writing. Failure of any of the tests shall result in rejection of the cylinder. Any defects shall be corrected by methods meeting the approval of the Contracting Officer or his authorized representative and a satisfactory retest conducted.

3.3.1.2 Miter Gate Cylinder Tests

a. Leakage (External). The rod end of the cylinder shall be pressurized to 3000 psi. The pressure shall be maintained for thirty (30) minutes to demonstrate there is zero leakage. The head end of the cylinder shall be pressurized to 3000 psi. The pressure shall be maintained for thirty (30) minutes to demonstrate there is zero leakage.

b. Leakage Around Piston. The cylinder shall be subjected to a differential pressure of 2000 psi across the piston for five (5) minutes and it shall be demonstrated that the leakage rate does not exceed 0.07 ounces per minute. The test shall be conducted at each end of the stroke.

3.3.1.3 Common Tests for All Hydraulic Cylinders

The cylinder shall be tested for breakaway pressure at the end and midpoint of the stroke. In each case the breakaway pressure shall not

SECTION 35 01 41 Page 7 exceed 50 psi. The cylinder shall be cycled in and out to demonstrate smooth operation. This shall be repeated to a minimum of six (6) times for the cylinder in each direction. The cycle times shall be those for normal operation which are shown on the drawings. All motion shall be smooth and quiet, any stickiness, hesitation, vibration or abnormal noise shall be cause for rejection of the cylinder.

3.4 SHIPPING OF CYLINDERS

The hydraulic cylinder shall be purged of air before shipping and filled with hydraulic fluid approved for use in the system and sealed to prevent corrosion of interior surfaces of the cylinder before being installed.

Provisions, satisfactory to the Contracting Officer, shall be made to allow for expansion of the fluid due to temperature changes.The equipment shall be packed in a manner acceptable to preserve the condition of the equipment as it left the fabricator's shop. The packaging shall clearly identify the contents and weight of the package. Submit details of Delivery of Equipment for approval. Shipping address and Barkley Lock Point of Contact can be found in Section 05 50 14 STRUCTURAL METAL

FABRICATIONS.

3.5 PAINTING

Exposed surfaces of operating machinery, except running surfaces of bushings, pins, and other wear surfaces, shall be painted as specified in Section 09 97 02, PAINTING: HYDRAULIC STRUCTURES.

-- End of Section --

SECTION 35 01 41 Page 8

2.3 PINS AND BUSHINGS