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************************************************************************** USACE / NAVFAC / AFCESA / NASA UFGS-41 24 27.00 10 (January 2008) ---------------------------------Preparing Activity: USACE (CW) Superseding UFGS-41 24 27.00 10 (April 2006) UNIFIED FACILITIES GUIDE SPECIFICATIONS References are in agreement with UMRL dated March 2008 ************************************************************************** SECTION TABLE OF CONTENTS DIVISION 41 - MATERIAL PROCESSING AND HANDLING EQUIPMENT SECTION 41 24 27.00 10 HYDRAULIC POWER SYSTEMS FOR CIVIL WORKS STRUCTURES 01/08 PART 1 GENERAL 1.1 PRODUCTS INSTALLED BUT NOT SUPPLIED 1.2 LUMP SUM PRICES 1.2.1 Payment 1.2.2 Unit of Measure 1.3 REFERENCES 1.4 SYSTEM DESCRIPTION 1.5 DESIGN AND PERFORMANCE REQUIREMENTS 1.5.1 Design Parameters 1.5.2 Allowable Stresses 1.5.2.1 Structural Items 1.5.2.2 Hydraulic Cylinders 1.5.2.3 Stress Concentration Factors 1.5.3 Connections 1.5.3.1 Pinned Connections 1.5.3.2 Shop Connections 1.5.3.3 Welded Connections 1.5.3.4 Structural Bolted Connections 1.6 SUBMITTALS 1.7 SCHEMATIC AND DRAWINGS 1.7.1 Shop Drawings 1.7.2 Fabrication Drawings 1.7.3 Shop Assembly Drawings 1.7.4 Hydraulic Schematic 1.7.5 Delivery Drawings 1.7.6 Field Installation Procedures 1.8 DELIVERY, STORAGE, AND HANDLING 1.8.1 Packaging 1.8.2 Shipping, Preservation, and Storage 1.9 WARRANTY 1.10 OPERATION AND MAINTENANCE PART 2 2.1 PRODUCTS MATERIALS AND MECHANICAL EQUIPMENT SECTION 41 24 27.00 10 Page 1 2.1.1 General 2.1.2 Standard Products 2.1.3 Hydraulic Cylinders (Standard Design) 2.1.3.1 Cylinder Tubes 2.1.3.2 Cylinder Heads and Caps 2.1.3.3 Pistons 2.1.3.4 Piston Rods (Standard Design) 2.1.4 Hydraulic Cylinders (Custom Design) 2.1.5 Hydraulic Cylinders (Corps Design) 2.1.5.1 Piston Rods (Corps Design) 2.1.5.2 Pistons 2.1.5.3 Piston Wear Rings 2.1.5.4 O-Ring Seals 2.1.5.5 Rod Wiper 2.1.5.6 [Piston and] Piston Rod Seals 2.1.5.7 Rod Seal Gland and Locking Device Flange 2.1.5.8 Hoist Locking Device 2.1.6 Hydraulic Power Unit 2.1.7 Oil Reservoirs 2.1.7.1 Reservoir Heater 2.1.7.2 Magnetic Separators 2.1.7.3 Air Breather 2.1.8 Pumps 2.1.9 Accumulators 2.1.10 Filters 2.1.11 Gauges 2.1.11.1 Pressure Gauges 2.1.11.2 Thermometer 2.1.12 Valves 2.1.12.1 Ball Valves 2.1.12.2 Needle Valves 2.1.12.3 Control Valves 2.1.12.4 Pressure Relief Valves 2.1.12.5 Unloading Valves 2.1.12.6 Supply Spring Loaded Check Valves 2.1.12.7 Return Spring Loaded Check Valves 2.1.12.8 Bleeder Valves 2.1.12.9 Pressure Snubbers 2.1.12.10 Counterbalance Valve 2.1.13 Piping 2.1.13.1 Pipe 2.1.13.2 Pipe Fittings 2.1.13.3 Unions 2.1.13.4 Hydraulic Tubing 2.1.13.5 Tube Fittings 2.1.13.6 Hose 2.1.14 Bolts, Nuts, and Washers 2.1.14.1 Carbon Steel Bolts and Nuts 2.1.14.2 Stainless Steel Bolts and Nuts 2.1.14.3 Flat Washers 2.1.15 Hydraulic Fluid 2.2 ELECTRICAL EQUIPMENT 2.2.1 Conduit, Duct, and Accessories 2.2.1.1 [Plastic Coated] Rigid Metal Conduit 2.2.1.2 Conduit Fittings 2.2.1.3 Conduit and Cabinet Supports 2.2.2 Cabinets and Boxes 2.2.3 Pump Motors 2.2.3.1 Rating SECTION 41 24 27.00 10 Page 2 2.2.3.2 Winding Insulation 2.2.3.3 Winding Heaters 2.2.3.4 Terminal Leads 2.2.4 Control Components 2.2.4.1 Control Devices and Wiring 2.2.4.2 Pressure Switches 2.2.4.3 Electronic Limit Switches 2.2.4.4 Transducer (Electromagnetic Position Sensor) 2.2.4.5 Remote Read-Out [Digital] [Analog] Display 2.2.4.6 Manual Switches 2.2.4.7 Relays 2.2.4.8 Indicating Lights 2.2.5 Control Consoles and Valve and Gauge Panels 2.2.5.1 Control Console Construction 2.2.5.2 Valve and Gauge Panel Construction 2.2.5.3 Nameplates and Instruction Plates 2.2.5.4 Security Provisions 2.2.5.5 Weather Protection 2.3 SHOP ASSEMBLY AND TESTING 2.3.1 Cleaning 2.3.2 Cylinder Tests 2.3.3 Hydraulic Power Units PART 3 EXECUTION 3.1 EXAMINAION 3.2 INSTALLATION 3.2.1 General 3.2.2 Cleaning and Flushing the System 3.2.3 Filling and Bleeding the System 3.3 PAINTING 3.4 ERECTION ENGINEER 3.5 FIELD TESTS AND INSPECTIONS 3.5.1 Field Testing 3.5.2 Proof Testing 3.5.3 Final Acceptance Tests 3.5.3.1 Initial Start-Up 3.5.3.2 Combined System Tests 3.5.3.3 Test Reports -- End of Section Table of Contents -- SECTION 41 24 27.00 10 Page 3 ************************************************************************** USACE / NAVFAC / AFCESA / NASA UFGS-41 24 27.00 10 (January 2008) ---------------------------------Preparing Activity: USACE (CW) Superseding UFGS-41 24 27.00 10 (April 2006) UNIFIED FACILITIES GUIDE SPECIFICATIONS References are in agreement with UMRL dated March 2008 ************************************************************************** SECTION 41 24 27.00 10 HYDRAULIC POWER SYSTEMS FOR CIVIL WORKS STRUCTURES 01/08 ************************************************************************** NOTE: This guide specification covers the requirements for hydraulic power systems to operate gates and other mechanisms at civil works structures. Edit this guide specification for project specific requirements by adding, deleting, or revising text. For bracketed items, choose applicable items(s) or insert appropriate information. Remove information and requirements not required in respective project, whether or not brackets are present. Comments and suggestions on this guide specification are welcome and should be directed to the technical proponent of the specification. A listing of technical proponents, including their organization designation and telephone number, is on the Internet. Recommended changes to a UFGS should be submitted as a Criteria Change Request (CCR). ************************************************************************** PART 1 1.1 GENERAL PRODUCTS INSTALLED BUT NOT SUPPLIED ************************************************************************** NOTE: List all property which will be furnished to the Contractor for installation. Materials and equipment which are purchased by supply contract by the Government to be furnished to the Contractor must be deleted from other portions of this specification. ************************************************************************** Pursuant to Contract Clause GOVERNMENT-FURNISHED PROPERTY (SHORT FORM), the Government will furnish to the Contractor the following property if required, to be incorporated or installed in the work. Such property will be furnished at the project site and the Contractor shall accept delivery. SECTION 41 24 27.00 10 Page 4 All such property shall be installed or incorporated into the work at the expense of the Contractor. Verify the quantity and condition of such Government-furnished property when delivered, acknowledge receipt thereof in writing and in case of damage to or shortage of such property, report within 24 hours, in writing, such damage or shortage. 1.2 LUMP SUM PRICES ************************************************************************** NOTE: If Section 01 22 00.00 10 MEASUREMENT AND PAYMENT is included in the project specifications, this paragraph title (LUMP SUM PRICES) should be deleted from this section and the remaining appropriately edited subparagraphs below should be inserted into Section 01 22 00.00 10. ************************************************************************** 1.2.1 Payment Payment will be made for costs associated with the hydraulic power system(s) as specified. 1.2.2 Unit of Measure Unit of measure: 1.3 lump sum. REFERENCES ************************************************************************** NOTE: This paragraph is used to list the publications cited in the text of the guide specification. The publications are referred to in the text by basic designation only and listed in this paragraph by organization, designation, date, and title. Use the Reference Wizard's Check Reference feature when you add a RID outside of the Section's Reference Article to automatically place the reference in the Reference Article. Also use the Reference Wizard's Check Reference feature to update the issue dates. References not used in the text will automatically be deleted from this section of the project specification when you choose to reconcile references in the publish print process. ************************************************************************** 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 WELDING SOCIETY (AWS) AWS D1.1/D1.1M (2006; Errata 2006) Structural Welding Code - Steel SECTION 41 24 27.00 10 Page 5 ASME INTERNATIONAL (ASME) ASME B16.11 (2005) Forged Fittings, Socket-Welding and Threaded ASME B31.1 (2007) Power Piping ASME B36.19M (2004) Stainless Steel Pipe ASME B40.100 (2006) Pressure Gauges and Gauge Attachments ASME BPVC SEC VIII D1 (2007) Boiler and Pressure Vessel Code; Section VIII, Pressure Vessels Division 1 - Basic Coverage ASTM INTERNATIONAL (ASTM) ASTM A 106/A 106M (2006a) Standard Specification for Seamless Carbon Steel Pipe for High-Temperature Service ASTM A 108 (2007) Standard Specification for Steel Bar, Carbon and Alloy, Cold-Finished ASTM A 181/A 181M (2006) Standard Specification for Carbon Steel Forgings, for General-Purpose Piping ASTM A 182/A 182M (2007a) Standard Specification for Forged or Rolled Alloy-Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service ASTM A 193/A 193M (2007) Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service ASTM A 194/A 194M (2007) Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High-Pressure or High-Temperature Service, or Both ASTM A 216/A 216M (2007) Standard Specification for Steel Castings, Carbon, Suitable for Fusion Welding, for High-Temperature Service ASTM A 234/A 234M (2007) Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature Service ASTM A 266/A 266M (2003a) Standard Specification for Carbon Steel Forgings for Pressure Vessel Components ASTM A 312/A 312M (2007) Standard Specification for Seamless, Welded, and Heavily Worked Austenitic Stainless Steel Pipes SECTION 41 24 27.00 10 Page 6 ASTM A 325 (2007a) Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength ASTM A 325M (2007) Standard Specification for Structural Bolts, Steel, Heat Treated, 830 Mpa Minimum Tensile Strength (Metric) ASTM A 354 (2007a) Standard Specification for Quenched and Tempered Alloy Steel Bolts, Studs, and Other Externally Threaded Fasteners ASTM A 516/A 516M (2006) Standard Specification for Pressure Vessel Plates, Carbon Steel, for Moderateand Lower-Temperature Service ASTM A 519 (2006) Standard Specification for Seamless Carbon and Alloy Steel Mechanical Tubing ASTM A 536 (1984; R 2004) Standard Specification for Ductile Iron Castings ASTM A 564/A 564M (2004) Standard Specification for Hot-Rolled and Cold-Finished Age-Hardening Stainless Steel Bars and Shapes ASTM A 576 (1990b; R 2006) Standard Specification for Steel Bars, Carbon, Hot-Wrought, Special Quality ASTM A 659/A 659M (2006) Standard Specification for Commercial Steel (CS), Sheet and Strip, Carbon (0.l6 Maximum to 0.25 Maximum Percent), Hot-Rolled ASTM A 705/A 705M (1995; R 2004) Standard Specification for Age-Hardening Stainless Steel Forgings ASTM A 789/A 789M (2005b) Standard Specification for Seamless and Welded Ferritic/Austenitic Stainless Steel Tubing for General Service ASTM B 505/B 505M (2007) Standard Specification for Copper-Base Alloy Continuous Castings ASTM B 584 (2006a) Standard Specification for Copper Alloy Sand Castings for General Applications ASTM D 3951 (1998; R 2004) Commercial Packaging ASTM F 844 (2007a) Washers, Steel, Plain (Flat), Unhardened for General Use ASTM G 85 (2002e1) Modified Salt Spray (Fog) Testing SECTION 41 24 27.00 10 Page 7 INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE) IEEE C57.12.70 (2000) Standard Terminal Markings and Connections for Distribution and Power Transformers INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO) ISO 1219-1 (2006) Fluid Power Systems and Components Graphic Symbols and Circuit Diagrams Part 1: Graphic Symbols for Conventional Use and Data-Processing Applications ISO 1219-2 (1995) Fluid Power Systems and Components Graphic Symbols and Circuit Diagrams Part 2: Circuit Diagrams ISO 16889 (1999) Hydraulic Fluid Power - Multi-Pass Method for Evaluating Filtration Performance of a Filter Element ISO 4021 (1992) Hydraulic Fluid Power - Particulate Contamination Analysis - Extraction of Fluid Samples from Lines of an Operating System ISO 5598 (1985) Fluid Power Systems and Components - Vocabulary NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA) NEMA C80.1 (2005) Standard for Electrical Rigid Steel Conduit (ERSC) NEMA ICS 1 (2000; R 2005) Standard for Industrial Control and Systems General Requirements NEMA ICS 2 (2000; Errata 2002; R 2005; Errata 2006) Standard for Industrial Control and Systems: Controllers, Contractors, and Overload Relays Rated Not More than 2000 Volts AC or 750 Volts DC: Part 8 Disconnect Devices for Use in Industrial Control Equipment NEMA ICS 6 (1993; R 2006) Standard for Industrial Controls and Systems Enclosures NEMA MG 1 (2007) Standard for Motors and Generators NEMA RN 1 (2005) Standard for Polyvinyl Chloride (PVC) Externally Coated Galvanized Rigid Steel Conduit and Intermediate Metal Conduit NATIONAL FLUID POWER ASSOCIATION (NFLPA) NFLPA T2.13.1 R3 (1998) Hydraulic Fluid Power Systems Practice for the Use of Fire Resistant SECTION 41 24 27.00 10 Page 8 Fluids in Industrial Systems NFLPA T2.24.1 R1 (2000; R 2005) Hydraulic Fluid Power Systems Standard for Stationary Industrial Machinery; Supplement to ISO 4413 NFLPA T3.16.2 R1 (1997; R 2005) Hydraulic Fluid Power Design for Nonintegral Industrial Reservoirs SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE) SAE ARP598 (2003; Rev C) Aerospace Microscopic Sizing and Counting of Particulate Contamination for Fluid Power Systems SAE J1165 (1979; R 1986) Reporting Cleanliness Levels of Hydraulic Fluids SAE J514 (2004) Hydraulic Tube Fittings UNDERWRITERS LABORATORIES (UL) UL 50 (2007) Standard for Enclosures for Electrical Equipment UL 6 (2007) Standard for Electrical Rigid Metal Conduit-Steel 1.4 SYSTEM DESCRIPTION The work covered by this section of the specifications consists of detailed requirements for the [design,] fabrication, shop assembly, testing, delivery, and installation of the hydraulic power systems for operation of the [intake gates] [slide gates] [control gates] [tainter gates] [miter gates] [butterfly valves] [hoisting equipment] [_____] as specified and as shown. 1.5 DESIGN AND PERFORMANCE REQUIREMENTS ************************************************************************** NOTE: Include this paragraph in the specifications when the Contractor is required to furnish the detailed design of the system. ************************************************************************** The contract drawings indicate the general arrangement of the hydraulic power system for operation of the [intake gates] [slide gates] [control gates] [tainter gates] [miter gates] [butterfly valves] [hoisting equipment] [_____], clearances necessitated by the structure or other equipment, maximum overall dimensions, and other pertinent features. Furnish the detailed design in conformity with NFLPA T2.24.1 R1, and the following design criteria. 1.5.1 Design Parameters ************************************************************************** NOTE: List all design parameters or criteria required by the Contractor to design the hydraulic SECTION 41 24 27.00 10 Page 9 power system. are: Possible design criteria to consider a. Maximum operating pressure b. Rated raising or retracting force c. Rated lowering or extending force d. Maximum raising or retracting time e. Maximum lowering or extending time f. Hoist stroke g. Critical or limiting dimensions h. Operating temperature range i. Duty cycles j. Any other unusual features ************************************************************************** The principal design parameters for the hydraulic power system are as follows: 1.5.2 1.5.2.1 Allowable Stresses Structural Items Structural items associated with the hydraulic power system, such as support beams, shall be designed to withstand the maximum force exerted by the hydraulic cylinder plus any dead loads with a factor of safety of 2 based on the yield strength of the materials involved. 1.5.2.2 Hydraulic Cylinders ************************************************************************** NOTE: Use telescopic hydraulic cylinders only for special retrofit applications where regular single or double acting cylinders cannot be used. ************************************************************************** Design the [telescopic] hydraulic cylinders to withstand the maximum operating pressure in the system with a factor of safety of 5, based on the ultimate strength of the material, or 2, based on the yield strength of the material. Apply a factor of safety of 3 to the compression load when designing the hydraulic cylinders to resist buckling. 1.5.2.3 Stress Concentration Factors Stress concentration factors shall be used where applicable. Reduction of allowable stresses to compensate for repeated cycles of loading is not required. 1.5.3 1.5.3.1 Connections Pinned Connections Design pinned hydraulic cylinder connections for field assembly as shown. 1.5.3.2 Shop Connections Design shop connections for assembly by means of welding or by bolting. SECTION 41 24 27.00 10 Page 10