USACE / NAVFAC / AFCESA / NASA UFGS-41 24 26 (January 2008)
----------------------------
Preparing Activity: USACE Superseding
UFGS-41 24 26 (April 2006)
UNIFIED FACILITIES GUIDE SPECIFICATIONS
References are in agreement with UMRL dated January 2009
SECTION 41 24 26
HYDRAULIC FLUID POWER SYSTEMS
01/08
NOTE: This guide specification covers the requirements for hydraulic fluid
power systems.
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 GENERAL
1.1 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.
[ASME INTERNATIONAL (ASME)ASME B1.1(2003; R 2008) Unified Inch Screw Threads (UN and UNR Thread Form)ASME B1.20.1(1983; R 2006) Pipe Threads, General Purpose (Inch)ASME B1.20.3(1976; R 2008) Dryseal Pipe Threads (Inch)ASME B16.11(2005) Forged Fittings, Socket-Welding and ThreadedASME B16.5(2003) Standard for Pipe Flanges and Flanged Fittings: NPS 1/2 Through NPS 24ASME B17.1(1967; R 2008) Keys and KeyseatsASME B17.2(1967; R 2008) Woodruff Keys and KeyseatsASME B18.2.1(1996; Addenda A 1999; Errata 2003; R 2005) Square and Hex Bolts and Screws (Inch Series)ASME B18.2.2(1987; R 2005) Standard for Square and Hex NutsASME B18.6.2(1998; R 2005) Slotted Head Cap Screws, Square Head Set Screws, and Slotted Headless Set Screws: Inch SeriesASME B31.1(2007; Addenda 2008) Power PipingASME B40.100(2005) Pressure Gauges and Gauge AttachmentsASME BPVC SEC IX(2007; Addenda 2008) Boiler and Pressure Vessel Code; Section IX, Welding and Brazing QualificationsASME BPVC SEC VIII D1(2007; Addenda 2008) Boiler and Pressure Vessel Code; Section VIII, Pressure Vessels Division 1 - Basic Coverage][ASSOCIATION FOR IRON AND STEEL TECHNOLOGY (AIST)AIST PB-224(1999) Stainless Steels][ASTM INTERNATIONAL (ASTM)ASTM A 106/A 106M(2008) Standard Specification for Seamless Carbon Steel Pipe for High-Temperature ServiceASTM A 108(2007) Standard Specification for Steel Bar, Carbon and Alloy, Cold-FinishedASTM A 182/A 182M(2008a) Standard Specification for Forged or Rolled Alloy-Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature ServiceASTM A 234/A 234M(2007) Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature ServiceASTM A 36/A 36M(2008) Standard Specification for Carbon Structural SteelASTM A 519(2006) Standard Specification for Seamless Carbon and Alloy Steel Mechanical TubingASTM A 574(2004e1) Standard Specification for Alloy Steel Socket-Head Cap ScrewsASTM A 574M(2004e1) Standard Specification for Alloy Steel Socket-Head Cap Screws (Metric)ASTM A 576(1990b; R 2006) Standard Specification for Steel Bars, Carbon, Hot-Wrought, Special QualityASTM A 659/A 659M(2006) Standard Specification for Commercial Steel (CS), Sheet and Strip, Carbon (0.l6 Maximum to 0.25 Maximum Percent), Hot-RolledASTM B 117(2007a) Standing Practice for Operating Salt Spray (Fog) ApparatusASTM D 3951(1998; R 2004) Commercial Packaging][INDUSTRIAL FASTENERS INSTITUTE (IFI)IFI 100/107(2002) Prevailing Torque Steel Hex and Hex Flange Nuts Regular and Light Hex Series][INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)ISO 10763(1994) Hydraulic Fluid Power - Plain-end, Seamless and Welded Precision Steel Tubes - Dimensions and Nominal Working PressuresISO 5598(2008) Fluid Power Systems and Components - Vocabulary][MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS INDUSTRY (MSS)MSS SP-58(2002) Standard for Pipe Hangers and Supports - Materials, Design and ManufactureMSS SP-69(2003; R 2004) Standard for Pipe Hangers and Supports - Selection and Application][NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)NEMA ICS 1(2000; R 2005; R 2008) Standard for Industrial Control and Systems General RequirementsNEMA 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 EquipmentNEMA ICS 6(1993; R 2006) Standard for Industrial Controls and Systems Enclosures][NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)NFPA 70(2007; AMD 1 2008) National Electrical Code - 2008 Edition][NATIONAL FLUID POWER ASSOCIATION (NFLPA)NFLPA B93.9(1969; R 2006) Symbols for Marking Electrical Leads and Ports on Fluid Power ValvesNFLPA T2.13.1 R4(2007) Recommended Practice – Hydraulic Fluid Power – Use Of Fire Resistant Fluids In Industrial Systems - Fifth EditionNFLPA T3.16.2 R1(1997; R 2005) Hydraulic Fluid Power - Design for Nonintegral Industrial ReservoirsNFLPA T3.28.9 R1(1989; R 2004) Fluid Power Systems and Products - Moving Parts Fluid Controls - Method of DiagrammingNFLPA T3.5.1 R2(2002) Hydraulic Fluid Power, - Valves, Mounting Surfaces][SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)SAE ARP598(2003; Rev C) Aerospace Microscopic Sizing and Counting of Particulate Contamination for Fluid Power SystemsSAE J1165(1979; R 1986) Reporting Cleanliness Levels of Hydraulic FluidsSAE J514(2004) Hydraulic Tube Fittings][UNDERWRITERS LABORATORIES (UL)UL Elec Equip Dir(2008) Electrical Appliance and Utilization Equipment Directory]1.2 DEFINITIONS
The definitions of terms having a unique meaning in fluid power technology shall be those given in ISO 5598.
1.3 SUBMITTALS
NOTE: Review submittal description (SD) definitions in Section 01 33 00 SUBMITTAL
PROCEDURES and edit the following list to reflect only the submittals required
for the project. Submittals should be kept to the minimum required for adequate
quality control.
A “G” following a submittal item indicates that the submittal requires Government
approval. Some submittals are already marked with a “G”. Only delete an existing
“G” if the submittal item is not complex and can be reviewed through the Contractor’s
Quality Control system. Only add a “G” if the submittal is sufficiently important
or complex in context of the project.
For submittals requiring Government approval on Army projects, a code of up
to three characters within the submittal tags may be used following the "G"
designation to indicate the approving authority. Codes for Army projects using
the Resident Management System (RMS) are: "AE" for Architect-Engineer; "DO"
for District Office (Engineering Division or other organization in the District
Office); "AO" for Area Office; "RO" for Resident Office; and "PO" for Project
Office. Codes following the "G" typically are not used for Navy, Air Force,
and NASA projects.
Choose the first bracketed item for Navy, Air Force and NASA projects, or choose
the second bracketed item for Army projects.
Government approval is required for submittals with a "G" designation; submittals not having a "G" designation
are for [Contractor Quality Control approval.][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 in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Detail Drawings[; G][; G, [_____]]
Installation[; G][; G, [_____]]
Drawings consisting of a complete list of equipment and materials, including manufacturer's
descriptive and technical literature; catalog cuts; performance charts and curves; and installation
instructions. Drawings shall also contain complete wiring and schematic diagrams and other
details required to demonstrate that the system has been coordinated and will properly function
as a unit. Drawings for motors, actuators, cylinders, pumps, controls, and other components
shall be included. Moving parts fluid control diagrams shall follow the methods in NFLPA T3.28.9 R1
. Drawings shall show proposed layout and anchorage of equipment and appurtenances, and equipment
relationship to other parts of the work including clearances required for maintenance and operation.
Details shall include loadings and types of frames, brackets, stanchions and other supports,
and pipe anchors for supported pipe and equipment. Foundation drawings shall include bolt setting
information for equipment indicated or required to have concrete foundations.
SD-03 Product Data
Spare Parts[; G][; G, [_____]]
Spare parts data for each different item of material and equipment specified.
Field Instructions[; G][; G, [_____]]
Proposed diagrams, instructions, and other sheets, before posting. Wiring and control diagrams
showing the complete layout of the entire system including equipment piping, valves, and control
sequence, framed under glass or in laminated plastic, shall be posted where indicated for local
operator and maintenance assistance. In addition, condensed operating instructions explaining
preventive maintenance procedures, methods of checking the system for normal safe operation,
and procedures for safely starting and stopping the system shall be typed, framed as specified
for the wiring and control diagrams, and posted beside the diagrams. The framed instructions
shall be posted before acceptance testing of the systems.
SD-04 Samples
Hydraulic Fluid
As a portion of the cleaning procedure, details of the sampling and testing operations and
the possible locations for withdrawing samples.
SD-06 Test Reports
Field Tests and Cleaning of Hydraulic Lines
Test reports in booklet form showing field tests performed to adjust each component and field
tests performed to prove compliance with the specified performance criteria, upon completion
and testing of the installed system. Each test report shall indicate the final position of
any system controls.
SD-07 Certificates
Welding
A copy of qualified procedures and a list of names and identification symbols of qualified
welders and welding operators.
SD-10 Operation and Maintenance Data
Operation and Maintenance Manuals
Field Tests and Cleaning of Hydraulic Lines
[Six] [_____] complete copies of operating instructions outlining the step-by-step procedures
required for system startup, operation, and shutdown. The instructions shall include the manufacturer's
name, model number, service manual, parts list, and brief description of all equipment and their
basic operating features. Field cleaning procedures designed to clean the system to the requirements
specified.
[Six] [_____] complete copies of maintenance instructions listing routine maintenance procedures,
possible breakdowns and repairs, and troubleshooting guides. The instructions shall include
equipment layout and simplified wiring and control diagrams of the system as installed.
1.4 QUALITY ASSURANCE
1.4.1 Welding
NOTE: If need exists for more stringent requirements for weldments, delete
this first subparagraph and use the second.
Perform welding for piping in accordance with qualified procedures using performance qualified welders and welding
operators. Procedures and welders shall be qualified in accordance with ASME BPVC SEC IX. Welding procedures
qualified by others, and welders and welding operators qualified by another employer may be accepted as permitted
by ASME B31.1. Notify the Contracting Officer 24 hours in advance of tests and the tests shall be performed
at the work site if practicable. Apply the welder's or welding operator's assigned symbol near each weld made
as a permanent record. Structural members shall be welded in accordance with Section 05 05 23 WELDING, STRUCTURAL.
1.4.2 Stringent Requirements
Welding and nondestructive testing procedures for piping are specified in Section 43 02 00 WELDING PRESSURE PIPING.
1.5 DELIVERY, STORAGE, AND HANDLING
Protect equipment delivered and placed in storage from the weather, humidity and temperature variation, dirt
and dust, or other contaminants.
1.6 EXTRA MATERIALS
Submit spare parts data for each different item of material and equipment specified, after approval of detail
drawings and not later than [_____] months prior to the date of beneficial occupancy. Include in the data a
complete list of parts and supplies, including lubricants and fluids, current unit prices, sources of supply,
and a list of the parts recommended by the manufacturer to be replaced after [1] [and] [3] year(s) of service.
PART 2 PRODUCTS
2.1 MATERIALS AND EQUIPMENT
2.1.1 Standard Products
Provide materials and equipment which are the standard products of a manufacturer regularly engaged in the manufacture
of the products and that essentially duplicate items that have been in satisfactory use for at least 2 years
prior to bid opening. Items of the same classification shall be identical, including equipment, assemblies,
parts, and components. Equipment shall be supported by a service organization that is, in the opinion of the
Contracting Officer, reasonably convenient to the site.
2.1.2 Nameplates
The manufacturer's name, address, and catalog number shall be permanently displayed on a plate securely attached
to each major item of equipment. Electrical equipment listed in UL Elec Equip Dir shall have UL label or registration
plate securely attached to the item of equipment.
2.1.3 Prevention of Corrosion
Provide fasteners and nameplates of corrosion-resistant materials. Surfaces of products, such as pumps, cylinders,
fluid motors, and similar components, of ferrous metal, where not otherwise specified, shall be given a corrosion-protective
coating at the factory. Manufacturers' standard coatings are acceptable, provided that coatings for interior
use can withstand continuous exposure to salt spray for 120 hours and coatings for exterior use for 504 hours.
The fog test shall conform to ASTM B 117. Immediately after completion of the test, coating shall show no signs
of wrinkling, cracking, or loss of adherence, and the specimen shall show no signs of corrosion creepage beyond
3 mm l/8 inch on either side of the scratch mark made as specified. If coated samples have successfully withstood
the salt spray test within the preceding 2 years, certificates will be acceptable in lieu of testing.
2.1.4 Equipment Guards and Access
Gears, couplings, projecting setscrews, keys, and other rotating parts shall be fully enclosed or properly guarded
to preclude personnel contact.
2.2 HYDRAULIC PUMPS
Pump volumetric ratings, tests, type, application, and mounting provisions shall be in accordance with manufacturer's
instructions and tested by approved methods for conformance with performance ratings. Pump rotation shall be
as indicated. Pumps shall be rated for continuous operation at a discharge pressure equal to or greater than
the pressure indicated. The rated discharge capacity of each pump shall not be less than indicated when the
pump is operated at the design input speed and discharge pressure.
2.2.1 Gear Pumps
Gear pumps shall be [fixed] [variable] [or] [_____] type. Covers and center section shall be [high strength
aluminum alloy die castings] [steel] [cast iron]. Thrust and wear plates shall be [heavy-duty bronze coated
steel] [bronze] [or] [_____]. Manufacturer's [standard] [or] [_____] shaft seals shall be used for rotary pumps.
Seals and wear plates and other wearing parts shall be replaceable and shall be suitable for the application,
duty, and temperatures involved.
2.2.2 Vane Pumps
2.2.2.1 Fixed Displacement Vane Pumps
Fixed displacement vane pumps shall be hydraulically balanced types. Housing shall be [high tensile strength
ductile iron] [cast iron] [_____]. Vanes shall be [heat treated high-speed tool steel] [_____]. Shaft and rotor
shall be [case hardened steel] [_____]. Shaft shall ride in bearings at both ends. Cam ring shall be [high
carbon chromium steel] [_____]. Double vane pumps shall be provided when indicated. Seals shall be [Buna N]
[nitrile rubber] [fluoroelastomer] [_____].
2.2.2.2 Variable Displacement Vane Pumps
Variable displacement vane pumps shall incorporate means for varying the pump displacement from zero to the maximum
rated quantity while the pump is operating against the system pressure indicated. Materials shall be as specified
for fixed vane pumps. Pumps shall be arranged for adjustment of discharge volume by [mechanical] [electrical]
[hydraulic] [pneumatic] means. The pump displacement shall be controlled by [integral automatic pressure compensation]
[adjustment screw] control. The pump casing shall be provided with a tapped outlet for connection of an external
drain line. Pump ports shall be [NPT] [tapped NPTF] [tapped for straight pipe threads] [drilled and faced for
flange connections] [socket weld].
2.2.3 Piston Pumps
Piston pumps shall be [cylinder block in-line type which reverses flow direction and controls flow rate by means
of external valve bank] [axial fixed] [axial variable] [or] [_____]. [Axial variable type shall be capable of
providing reversed flow with constant direction of input shaft rotation.] [Axial variable type shall be suitable
for control of displacement [and direction of flow] by [manual] [mechanical] [hydraulic] [electric] [pneumatic]
devices.] [Manually adjustable maximum and minimum limits of displacement in each direction of flow shall be
provided.]
2.3 RESERVOIRS
Unless otherwise indicated, nonintegral reservoirs shall conform to the general requirements of NFLPA T3.16.2 R1
.
2.3.1 Basic Construction
NOTE: Insert the appropriate number in the blanks. Variations in the fluid
line connections are permitted at the designer's option.
Each reservoir shall be breather type of welded [carbon steel] [corrosion-resisting steel] construction with
removable cleanout plates provided at each end. Cleanout plates shall have gaskets and shall be securely fastened
to the reservoir end plates. Each reservoir shall be sloped to a drain plug located at the low point. The bottom
of the reservoir shall have a minimum clearance of 150 mm 6 inches above the floor. The legs or base of floor-mounted
reservoirs shall have suitable holes for fasteners. A minimum of one interior baffle shall be provided to separate
the return line from the pump suction line. A filter breather cap and fill port with a [_____] mesh strainer
shall be provided. Port cap shall have retaining chain. A separate steel mounting plate at least 19 mm 3/4
inch thick shall be provided to support the pumping unit.
2.3.2 Fluid Line Connections
The pump suction line shall extend as far as practicable below the low fluid level but shall clear the bottom
of the tank by a distance equal to 1-1/2 times the nominal line size. The suction line shall be equipped with
a [100 by 100] [_____] mesh externally mounted strainer having a rated capacity not less than twice the pump
discharge capacity. Strainer material for filters at both the suction line and the fill inlet shall be [55-mesh
nylon] [30-mesh brass] [or] [30-mesh stainless steel] material compatible with the reservoir material and the
hydraulic fluid. Drain lines shall extend below fluid level. [Extra return and drain line connections shall
be built into reservoir.]
2.3.3 Magnetic Separators
Manufacturer's standard magnetic separators shall be provided in the reservoir. Magnetic separator shall consist
of a high-strength permanent magnet arranged for rigid mounting with the poles of the magnet exposed to the fluid
in the reservoir. The magnet shall be [combined in the construction of the fill strainer] [mounted on a removable
rod assembly installed through the top of the reservoir] [or] [incorporated in the bottom drain plug]. [The
drain plug type installation shall incorporate an automatic valve arranged to permit removal of the magnetic
separator for inspection without loss of fluid from the reservoir.] [The drain plug type installation shall
include provisions for automatic chip detection without removal of the plug.]
2.3.4 Accessories
NOTE: Thermometers may be deleted at the designer's option. Where remote operation
is anticipated, the design shall include a low-level alarm and pump cutoff device.
Manufacturer's standard recessed or protected oil level indicator shall be mounted in a readily visible location
in proximity to the filler opening. The fluid level gauge shall be clearly marked to indicate the maximum and
minimum design operating levels and the fluid level when the system is idle. [Manufacturer's standard direct
indicating thermometer shall be provided to indicate fluid temperature in the reservoir. Mercury shall not be
used in thermometers. The thermometer shall be of the bimetallic type mounted directly on the reservoir top.
The thermometer shall have 90 mm 3-1/2 inch diameter dial with black markings on a white or aluminum background.
Case and stem shall be corrosion-resisting steel. Scale range shall be minus 7 to 115 degrees C 20 to 240 degrees
F. The thermometer shall be remote reading, capillary tube-and-bulb type. The thermometer shall have a dial
not less than 90 mm 3-1/2 inches in diameter with black figures on a white or aluminum background. Indicating
head shall be of the [flush] [surface] mounting type. Case shall be [cast iron] [cast brass] with black enamel
finish. Bulb and capillary tube shall be corrosion-resisting steel.] [A low-level alarm and pump cutoff device
shall be provided as indicated.]
2.4 CYLINDERS
NOTE: Unless the designer needs to make the choices, because of unique criteria
situations, selection of materials and configurations should remain as Contractor's
options and the brackets should be removed.
Hydraulic cylinder shall be one of the types listed in ISO 5598, and as specified or indicated, of tie rod design,
square head standard construction. The pressure rating of the cylinder shall not be less than the maximum system
pressure indicated. The manufacturer shall produce evidence that each cylinder was hydrostatically tested to
200 percent of the severest service rating and that dynamic seals are suitable for both frequent and infrequent
operation and are capable of not less than 500,000 cycles of operation in systems properly maintained. Cylinders
shall have bore, stroke, and rod diameter as indicated. NFPA mounting style shall be as indicated. The hydraulic
cylinder shall have [adjustable] [nonadjustable] cushions on [cap end only] [rod end only] [both ends]. [Cushions
shall have free reverse flow check valves.] Cylinders shall be provided with double end rods where indicated.
Ports shall be [NPTF] [SAE straight-thread O-ring] [_____].
2.4.1 Cylinder Tube
Cylinder tube shall be machined from ASTM A 519, Grade 1018, heavy wall seamless steel tubing and shall have
the bore honed to a 254 to 381 nanometers 10 to 15 microinch rms surface finish.
2.4.2 Cylinder Heads and Caps
Cylinder heads and caps shall be fabricated from ASTM A 576, Grade 1018, steel bar stock and machine-finished
on all surfaces. The cylinder head shall be equipped with rod seal and external dirt wiper and shall have rod
bushing piloted into head to ensure concentricity. [Rod bushing shall be removable without the use of special
tools and without removing tie rods or cylinder head.] Attachment of cylinder tube to head and cap shall be
[by steel tie rods having a minimum yield strength of 690 MPa 100,000 psi] [or] [as indicated]. Removable attachments
shall have the cylinder tube end seals arranged to seal with pressure and shall be designed to prevent shearing
and extrusion and to provide axial metal backup.
2.4.3 Pistons
Pistons shall be precision fitted to the cylinder body bore. Pistons shall be [fine-grained cast iron] [_____]
and shall be designed and equipped with [zero leakage cup-type seals] [bronze-filled polytetrafluoroethylene
seals with phenolic wear rings] [automotive-type lap-sealed cast iron rings]. The design shall protect piston
seals from blow-out and over squeeze. [Cups shall be self-regulating and shall automatically compensate for
wear.]
2.4.4 Piston Rods
Piston rods shall be made of [medium carbon steel of yield strengths of 620 to 690 MPa 90,000 to 100,000 psi
for rods 16 through 102 mm 5/8 through 4 inches in diameter] [620 to 760 MPa 90,000 to 110,000 psi high tensile
strength steel using ASTM A 108, Type C 1045, for rods 16 to 64 mm 5/8 to 2-1/2 inches in diameter and ASTM A 108
, Type CR 4140 for rods 76 to 254 mm 3 to 10 inches in diameter]. Rods shall be case hardened to 50-54 Rockwell
C, polished to 254 nanometers 10 microinch rms surface finish or better, and hard-chrome plated to 0.0003 minimum
thickness.
2.5 FLUID MOTORS
2.5.1 Vane Motors
Fixed displacement vane motors shall be [hydraulically balanced] [high torque, low speed] [_____] type. Motors
shall be rated for continuous operation at a system pressure equal to or greater than the pressure shown. The
motors shall be capable of producing an actual output torque not less than shown when operating at the indicated
supply pressure. Actual displacement shall not exceed the value shown. The shaft shall be [straight keyed]
[threaded] [or] [splined]. Shafts shall be capable of rotation in either direction. The motor casing shall
be provided with a tapped outlet for connection of an external drain line. Motor ports shall be [tapped NPTF]
[tapped with straight pipe threads] [drilled and faced for flange connections]. Filtration shall be 10 microns
or less. [Displacement selector valve shall be provided.]
2.5.2 Piston Motors
Piston motors shall be [axial inline] [or] [angle] type and shall be designed as [fixed] [variable] displacement
type. Variable displacement type shall be capable of providing reversed rotation with constant direction of
fluid flow. Variable displacement type shall be suitable for control of displacement and direction of rotation
by [manual] [mechanical] [hydraulic] [electric] [pneumatic] [_____] devices. Manually adjustable maximum and
minimum limits of displacement shall be provided. Manually adjustable maximum limits of displacement in each
direction of rotation shall be provided. The drive shaft shall be supported by heavy-duty antifriction bearings.
The motor casing shall be provided with a tapped outlet for connection of an external drain line. Motor ports
shall be [tapped NPTF] [tapped with straight pipe threads] [drilled and faced for flange connections]. Filtration
shall be 10 microns.
2.6 ACCUMULATORS
Accumulators shall be [piston] [bladder] type and shall be [gas pressure] [_____] loaded. Accumulator fluid
capacity shall not be less than indicated. Accumulators shall be designed for a rated working pressure not less
than the maximum system pressure and shall have a safety factor of not less than four. Fluid ports shall be
[tapped NPTF] [tapped for straight pipe threads] [drilled, tapped, and faced for flange connections]. Gas and
accessories needed to recharge the accumulator with gas shall be provided as indicated.
2.6.1 Piston Type
Cylinder shall be [single] [double] wall type constructed from seamless steel tubing and wrought or forged steel
end caps. Piston shall be [cast iron] [aluminum] [_____] and shall be equipped with O-ring type seals with antiextrusion
backup guide rings. Accumulators 152 mm 6 inches and larger shall be designed and constructed in accordance
with the requirements of ASME BPVC SEC VIII D1. The accumulator shall be equipped with a safety device to release
excessive pressure before the burst pressure is reached. A high-pressure gas charging valve shall be provided.
The charging valve shall be protected from damage by recessed type construction or by a protective cap. Safety
bleed holes in the shell and a gas valve or other means shall be included to positively prevent disassembly of
the accumulator until all gas and fluid pressures have been released.
2.6.2 Bladder Type
Shells shall be one-piece alloy steel construction without welds, seams, or joints. The fluid discharge port
shall be provided with a spring-loaded poppet valve arranged to close automatically upon discharge of all of
the fluid to prevent extrusion of the bladder. An antiextrusion ring shall be provided when recommended by the
manufacturer. The design shall permit disassembly for repair without removing the accumulator from the system.
The method of disassembly shall include provisions to prevent disassembly until all gas and fluid have been bled.
A gas charging valve complete with protective cap and replaceable valve core shall be provided. The design shall
incorporate suitable means to release excessive pressure before the burst pressure is reached.
2.7 VALVES
Valves used in the hydraulic system lines shall be specially designed and rated for use in hydraulic systems.
Valves used in pneumatic lines, such as air-oil booster systems and gas-loaded accumulators, shall be specifically
designed and rated for use in pneumatic systems. Valves shall have published pressure ratings not less than
the maximum pressure ratings indicated for the circuit in which installed. Identification of ports, pilot and
solenoid actuators and solenoid leads shall be as indicated by symbols conforming to NFLPA B93.9.
2.7.1 Directional Control Valves
Directional control valves shall be [ball] [plug] [spool (plunger)] [sliding plate] [linear sliding plate] [or]
[rotating sliding plate] design as indicated. Directional control valves shall be [check] [four-way] [selector
(diversion)] [straightway] [or] [three-way] functional type.
2.7.2 Flow Control Valves
Flow control valves shall be [ball] [diaphragm] [disc (globe)] [swing disc] [gate] [spreader gate] [wedge gate]
[needle] [plug] [or] [poppet] design as indicated. Flow control valves shall be [shutoff] [sequence] [flow dividing]
[flow dividing, compensated] [metering] [deceleration] [pressure compensated] [pressure-temperature compensated]
functional type.
2.7.3 Pressure Control Valves
Pressure control valves shall be [counterbalance] [decompression] [load dividing] [pressure reducing] [relief]
[safety relief] [or] [unloading] type as indicated.
2.7.4 Valve Actuators
Valve actuators shall be [manual] [mechanical] [solenoid] [or] [pilot] as indicated. [Pilot actuators shall
be [barrier] [differential area] [differential pressure] [or] [solenoid controlled] as shown.]
2.7.5 Valve Mounting
Valve mounting provisions shall be [base] [in-line] [manifold] [or] [subplate] as indicated. Mounting surfaces,
dimensional criteria, and general criteria of subplate mounted type valves for 20.7 MPa3,000 psi maximum hydraulic
service shall conform to NFLPA T3.5.1 R2.
2.7.6 Valve Materials and Components
2.7.6.1 Valve Bodies
Valve bodies shall be [steel] [brass] [cast iron] [aluminum] [or] [_____] as indicated. Valve body bores which
contain pistons, poppets or spools shall be finished to 203 nanometers 8 microinch rms and shall be round and
straight to within 1.3 micrometers 50 millionths of an inch.
2.7.6.2 Poppet Material
Poppet material shall be [soft seal (nitrile rubber)] [nylon] [solid metal] [or] [_____].
2.7.6.3 Port Style and Port Connections
Port style shall be [NPTF] [SAE straight thread] [flare tube] [or] [_____]. Port connections shall be for [tapped
conductors] [or] [socket weld couplings].
2.7.6.4 Seal Compound
Seal compound shall be [Buna N] [nitrile rubber] [or] [fluoroelastomer].
2.7.6.5 Spools
Spools shall be steel case hardened to 50 Rockwell C, minimum. Spool movement shall be by [manual actuation]
[mechanical actuation] [hydraulic pilot] [air pilot] [or] [solenoid]. [Manual actuator shall be a [push button]
[hand lever] [or] [foot pedal].] [Air pilot operated control valves shall have bronze housings and stainless
steel spools.]
2.7.6.6 Solenoids
Solenoids shall be [ac] [or] [dc] [wet armature] type and [pull-in] [or] [drop-out] style. Solenoids shall be
[spring offset, single] [spring centered, double] [or] [detented, double] model. Solenoids shall be moisture
proof where indicated.
2.8 INTENSIFIERS (BOOSTERS)
Intensifiers Boosters shall be [oil-to-oil] [air-to-oil] type. The driving cylinder bore size and operating
fluid medium, the mounting style, and a manufacturer's series identification (or equal) shall be as shown. [For
cylinder-to-ram (piston) intensifiers, ram diameter shall be as shown.] [For cylinder-to-cylinder units, output
cylinder bore shall be as indicated.] Inlet and outlet pressures and intensification ratio shall be as indicated.
Intensifier shall be designed for use with petroleum base hydraulic fluid unless otherwise indicated. The manufacturer
shall produce evidence that all dynamic seals are suitable for both frequent and infrequent operation and are
capable of not less than 500,000 cycles of operation in systems properly maintained. The intensifier shall be
capable of continuous operation under severe operating conditions at discharge pressures up to the indicated
maximum circuit pressure.
2.9 FLUID COOLERS (HEAT EXCHANGERS)
Fluid coolers (Heat Exchangers) shall be [water-cooled] [or] [air-cooled] type and shall have the cooling capacity
indicated.
2.9.1 Air-Cooled
Air-cooled type shall have a core of [oval-tube and plate-fin] [round-tube plate-fin] [or] [individual finned
round tubes]. The cooler shall be equipped with an electric motor-driven fan, selected to provide the air flow
volume through the core to ensure that the cooling requirements are met. Operating sound level of fan and motor
shall not exceed 85 dBA.
2.9.2 Water-Cooled
Water-cooled type shall be [shell-and-tube] [plate type] construction. [Shell-and-tube type shall be arranged
to handle water through the tubes and the hydraulic fluid through the shell.] [Shell-and-tube construction shall
be arranged as [U-tube] [straight tube] [fixed tube bundle] [straight tube, removable bundle] type.]
2.10 FILTRATION EQUIPMENT
Fluid filters shall be located as indicated. Nominal and absolute ratings shall not exceed the values indicated.
Filters shall be [depth] [surface] type. Pressure drop through each filter shall not exceed the value indicated
at the given maximum flow rate. Elements for depth type filters shall be [resin-coated] [paper] [synthetic fiber]
[vinyl membrane] type. Elements for surface filters shall be [wire cloth] [nylon cloth]. [Filter casings for
installation in pressure lines shall have a working pressure rating in excess of the specified maximum pump discharge
pressure.] [Filter casing for separate filtration circuits shall have a rated working pressure in excess of the
maximum pressure of the filter circuit.] Filters shall be provided with [adjustable] [nonadjustable] [internal]
[external] bypass. [An indicator shall be provided to show when the bypass has opened.] The cracking pressure
of the bypass on pressure filters shall be as indicated. The cracking pressure of the bypass on filters installed
on the suction side of pumps shall be as required by the pump manufacturer.
2.11 LINES AND FITTINGS
NOTE: Unless the designer needs to make the choices, because of unique criteria
situations, selection of materials and configurations should remain as Contractor's
options and the brackets should be removed.
The contents of these paragraphs are dependent on design requirements which
may necessitate revision or expansion to cover different conditions and standards.
In some cases, system design may permit combining test connections and drain
or vent valves; in other cases, separate valves for each function will be required.
Piping and tubing connections shall be designed and installed to permit quick removal and reassembly with hand
tools.
2.11.1 Pipe
Unless otherwise indicated, hydraulic pipe shall be seamless steel pipe conforming to ASTM A 106/A 106M, Grade
B. Piping weight class shall be [standard] [extra strong] [double extra strong] [Schedule 160]. Pipe shall
conform to the cleanliness requirements of ISO 10763.
2.11.2 Pipe Fittings and Flanges
Pipe fittings shall be steel. Fittings that incorporate separate synthetic, or metal-to-metal seals, or seals
that seal with pressure, shall be equipped with Unified National Fine (UNF) straight thread port connections.
Fittings that incorporate synthetic, or metal-to-metal seals, or seals that seal with pressure, may be used with
pipe thread port connections. Pipe flanges shall be steel, [_____] MPa psi steam working pressure rated, and
shall be faced for use with metallic O-ring gaskets. Flange bolts shall be steel and shall have steel self-locking
nuts. Mechanical connections, proven suitable for the pressure and service, may be used instead of flanged connections.
The seals shall be compatible with the hydraulic fluid used in the system. Threaded fittings shall conform to
ASME B16.11 forged carbon steel, pressure class Class [2000] [3000] [6000] [2000] [3000] [6000] pounds threaded
in conformance with ASME B1.20.1 or ASME B1.20.3. Welded fittings shall conform to ASTM A 234/A 234M, Grade
WPB. Flanges shall conform to ASTM A 182/A 182M, grade suitable for pipe to which attached. Facing on flanges
shall be in accordance with ASME B16.5.
2.11.3 Tubing and Fittings
Tubing shall be seamless or welded steel tubing conforming to ISO 10763.
2.11.3.1 Wall Thickness
Wall thickness for each size not otherwise indicated shall be selected to provide a safety factor of six based
on the manufacturer's ratings for burst strength.
2.11.3.2 Fittings
Solderless steel fittings shall be used. Connections may be flared, flareless, self-flaring, or equivalent.
When flared-type fittings are used, the tubing end of the connector body, nut, and sleeve when used, shall be
37 degrees from center (74 degrees included angle), and shall conform to SAE J514 for minimum performance requirements.
Copies of test reports for all tubing fittings shall be submitted with detail drawings. Adapters for connecting
tubing to threaded pipe ports shall be straight thread type with locknut, washer, and O-ring seal. Fittings
that incorporate separate synthetic or metal-to-metal seals, or seals that seal with pressure shall have UNF
straight-thread port connections. Fittings that incorporate synthetic, or metal-to-metal seals, or seals that
seal with pressure may be used with pipe thread port connections.
2.11.4 Flexible Lines
Flexible hydraulic lines shall be wire reinforced, high-pressure type hose with synthetic rubber lining and outer
cover. Synthetic rubber shall be selected for maximum compatibility with the hydraulic fluid specified for use
in the system. Flexible hose shall be rated by the manufacturer for a working pressure not lower than the system
operating pressure indicated. Fittings shall be specifically designed for use with the hose selected and shall
be as recommended by the hose manufacturer. Fittings shall be [stainless steel] [carbon steel] and shall have
straight or elbow ends as best suited to the installation conditions. Fittings shall be [reusable] [permanently
attached] type. Each hose assembly shall be factory assembled using procedures and tools recommended by the
manufacturer of the hose.
2.11.5 Manifolds
Manifolds shall be provided where indicated. Each manifold shall be [cast] [machined from solid plate] [constructed
by laminating two or more plates together by furnace brazing]. Ports and passages shall be machined smooth and
shall be free of burrs and sharp edges. Surfaces to which valves and other components will be mounted shall
be machined smooth and flat. Counterbores to hold O-ring port seals shall be machined to dimensions recommended
by the O-ring manufacturer.
2.12 HYDRAULIC FLUID
A sufficient amount of hydraulic fluid, of the type specified and as recommended by the fluid manufacturer, shall
be supplied to completely fill the system initially plus at least 10 percent additional reserve fluid. Extra
fluid to make up all losses resulting from venting operations, from servicing filtration equipment, from leakage
and from all other causes before final acceptance also shall be provided. The fluid level shall be checked and
brought to the proper operating level immediately after satisfactory completion of final acceptance tests. The
hydraulic fluid shall be delivered to the site in unopened containers with factory seals intact. Containers
shall be clearly labeled in accordance with ASTM D 3951. Hydraulic fluids shall be certified by the manufacturer
as fire-resistant in conformance with NFLPA T2.13.1 R4. Fluid shall be [water-glycol] [synthetic] [water-in-oil
emulsion] type. Fresh hydraulic fluid shall be filtered to 10 micron level.
2.13 PACKING, GASKETS, AND SEALS
Hydraulic components shall be equipped with seals, packings, gaskets, and O-rings selected and recommended by
the respective manufacturers for maximum compatibility with the particular hydraulic fluid specified for use
in the system.
2.13.1 Static Seals
Static-type seals shall be arranged to seal with pressure and shall be provided with backup rings or other approved
confining devices to prevent material extrusion during expansion and contraction resulting from pressure and
temperature changes. Static-type seals shall be continuous rings.
2.13.2 Dynamic Seals
Dynamic seals may be lip, cup, V-ring, U-ring, flange, or squeeze type, unless otherwise specified or indicated.
Split metallic rings (automotive type) may be used only when specifically indicated.
2.14 ACCESSORIES
Accessories shall conform to the following:
2.14.1 Bolts, Nuts and Cap Screws
ASME B18.2.1, ASME B18.2.2, ASME B18.6.2 or ASTM A 574M ASTM A 574, as applicable. All bolts, cap screws, and
nuts not otherwise indicated or specified shall be medium carbon steel and shall be cadmium plated. Threads
shall conform to ASME B1.1.
2.14.2 Locknuts
IFI 100/107 for hexagon locknuts, prevailing torque type, or a type standard with the manufacturer provided they
meet or exceed the requirements of the IFI specifications.
2.14.3 Setscrews
ASME B18.6.2 unless otherwise indicated or specified. Setscrews shall not be used for transmitting torsion.
2.14.4 Methods of Securing Fasteners
All fasteners not secured by mechanical devices, such as lock washers, cotter pins, safety wire, or locknuts,
shall have the threaded portion of the fastener coated with sealing/locking compound, Grade E or Grade B, as
applicable, before installation. Fasteners shall be cleaned of all rust-inhibiting compounds and lubricants
before applying the sealing/locking compound.
2.14.5 Keys and Keyways
ASME B17.1 or ASME B17.2, unless otherwise specified or required.
2.14.6 Pipe Hangers and Supports
MSS SP-58 and MSS SP-69.
2.15 SHAFT COUPLINGS
Shaft Couplings shall have strength equal to the full strength of the shafting which they connect and shall be
pressed and keyed thereon. In determining the coupling capacity, the manufacturer's rating shall be divided
by a service factor of [1.5] [_____].
2.15.1 Flexible Couplings
Unless otherwise indicated, flexible couplings shall be of forged steel and shall transmit torque by [a steel
grid spring fitted into grooves in the periphery of the coupling's hubs] [external gear teeth on hubs engaging
in internal gear teeth in the coupling sleeves] [or] [flexible annular discs bolted alternately to the end flanges
and center member by body bound bolts]. [Flexible couplings of the [geared] [or] [grid] type shall be fully
enclosed and sealed to retain lubricant and shall be oil-tight under both static and operating conditions.]
2.15.2 Rigid Couplings
Rigid couplings shall be cast or forged steel and shall be flanged or compression type with recessed bolts.
2.16 PRESSURE GAUGES
Pressure Gauges shall conform to ASME B40.100 with [black enameled corrosion-resisting metal case] [phenolic
case]. The scale range of the gauge shall be approximately twice the maximum pressure of the circuit in which
installed. Gauges shall be safety type with solid fronts and blowout backs. Each gauge shall be provided with
an approved gauge snubber. All permanently installed gauges shall have a shutoff valve arrangement to permit
isolation of the gauge and snubber from the rest of the system.
2.17 SHIMS
Shims shall be provided in graduated thicknesses which shall permit adjustment in increments of 0.13 mm 0.005
inches from 0 to 6.4 mm 0 to 1/4 inch. Shims for use between machinery components, subassemblies, or machinery
bases and mounting brackets and unfinished surfaces of structural member shall provide adjustment in increments
of 0.79 mm 1/32 inch from 6.4 mm 1/4 inch to 150 percent of the shim allowance indicated. Tapered shims shall
be provided as required to accurately align machinery components and bases which are mounted directly on unfinished
structural steel surfaces. Field measurements shall be taken to determine the exact amount of taper required
to obtain proper alignment. Material for all shims shall be AIST PB-224, Types 304 or 316 unless otherwise indicated.
2.18 EQUIPMENT BASES
Nonintegral equipment bases including brackets and mounts shall be all-welded construction and shall be fabricated
of ASTM A 36/A 36M steel. After installation and final adjustment of all the system components on the equipment
bases in the shop, each piece of equipment shall be positively secured in place by dowels to ensure accurate
location during installation in the field. Shear blocks may only be used where installation of dowels is completely
impractical.
2.19 CONTROL COMPONENTS
NOTE: Where it is desired to control, coordinate, and program components of
a hydraulic fluid power system to achieve synchronization of cylinders or components
or to achieve a sequence of operations in several modes, system requirements
and specifications shall be tailored for the job.
a. The programmed controller is used in modern fluid power systems where a
series of operations is to be performed in a sequential order on each cycle.
It can be programmed to cause a number of hydraulic cylinders or motors to follow
a sequential order of operations, extending and retracting, starting and stopping,
during each cycle.
b. The controller can be programmable, consisting of a console plugged into
Central Processing Unit (CPU), or a specialized microcomputer system that can
be custom programmed to control a wide variety of electronic and electrohydraulic
systems and components, and has the capability to interface with other controls
and transducers.
c. To counter unwanted oscillation in some types of actuators, where axis movement
or load change causes actuator deflection coupled with the mass of the actuator
system and results in damaging or undesired oscillation, microcomputer-based
electronic modules can be programmed to compute velocity and acceleration dampening
oscillation and permitting faster operating speed and greater accuracy. This
eliminates the need for actuator sensors to provide position, speed, and acceleration
feedback, and eliminates harnesses and connectors associated with sensors.
d. Electronic control components are used to build electrohydraulic control
systems and include power supplies and amplifier modules to supply proper input
to the various servo valves, control pumps, pressure valves, and flow control
valves that comprise an electrohydraulic controlled system.
2.19.1 Control Devices and Wiring
NOTE: When explosion proof enclosures are required, fill in the blanks indicating
the hazard classification. Where more than one type of enclosure is required,
expand the sentence to indicate where or how each type is used.
Manual or automatic control protective or signal devices required for the specified operation and all control
wiring for these controls and devices shall be provided whether indicated or not. Electrical control devices
shall have minimum current and voltage ratings in accordance with the requirements of NEMA ICS 2 contact rating
designation A 300, as applicable, unless larger ratings are indicated or required. Control devices shall be
provided with the number and arrangement of contacts required to perform the specified control functions. Devices
shall be provided with or installed in [general purpose] [weatherproof] [NEMA Type 4 for [exterior] [interior]
[hazardous] [nonhazardous] application] [corrosion-resistant] [NFPA 70 Class [_____] Division [_____], explosion-proof]
enclosures as indicated. Components shall be electronically and electrohydraulically controlled as indicated.
2.19.2 Pressure Switches
NOTE: Where differential pressure limits are essential to the design, the particular
limits should be stated on the drawings. Where specific types of actuators
are required, include the applicable type or types. Where more than one type
is used, expand the sentence to include where or how each type is used. Where
adjustable-setting switches are used, delete the brackets from the sentence
regarding the upper limit of adjustment. If manual reset switches are used,
indicate on the drawings those switches which are included, and delete the brackets
from the last sentence.
Pressure switches shall have the operating pressure [settings] [and] [ranges] [and maximum allowable differentials]
indicated. Actuators shall be of the [bellows] [piston] [Bourdon tube] [diaphragm] type [indicated] [required
for the operating conditions]. Actuators shall have a rated proof or shall withstand pressure of not less than
150 percent of the maximum possible pressures for the systems in which they are installed. [The maximum setting
for switches with an adjustable range of operating pressures shall be limited to 80 percent of the proof pressure
ratings.] Actuators shall be fabricated from materials which are compatible with the fluids employed. Switches
shall be the automatic reset type [except where manual reset type are indicated].
2.19.3 Limit Switches
NOTE: Where a very critical switch operation is required, such as a safety
stop, positive drive switch installations are sometimes used. If a normally-closed
contact should weld closed accidentally, the positive drive will either break
the weld and open the circuit or destroy itself in the attempt. Where such
drives are required, delete the brackets in the appropriate sentence and include
suitable information on the drawings. If manual reset switches are used, indicate
them on the drawings and delete the brackets from the last sentence of paragraph
"Pressure Switches."
Limit switches shall have activating mechanisms of the [roller arm] [push rod] [plunger] [fork] type [indicated]
[required to detect the particular positions]. Except where manual reset type is specifically indicated, activating
mechanisms and switch mountings shall be arranged so that over travel of the monitored member will not damage
the activator and switch.
2.19.4 Manual Switches
Manually-operated switches, including pushbutton switches, selector switches and key-operated switches, shall
be heavy-duty oil-tight type conforming to the requirements of NEMA ICS 1. Switches shall be momentary contact
type with standard operators [except where maintained contacts or special operators, such as mushroom head, illuminated
button, and latching button are indicated].
2.19.5 Relays
Relays used in control circuits shall be industrial magnetic control relays conforming to NEMA ICS 2 contact
rating designation A 300, except where other ratings are indicated. Relays shall be applied in control circuits
in such a manner that proper control functions shall be obtained regardless of whether the contacts are overlapping
or nonoverlapping.
2.19.6 Timers
Timing devices shall be electrically-activated [synchronous motor] [oil dashpot] [pneumatically] [electrically]
[_____] -timed type with adjustable timing ranges as indicated. Where the adjustment range is not indicated,
range shall be adjustable from at least 50 to 150 percent of the delay setting indicated, specified, or required.
Timers shall provide time delay on energizing and shall be of the automatic reset type unless otherwise indicated.
2.19.7 Indicating Lights
Indicating lights shall be the oil-tight type with jewel color as indicated. Light unit shall be the integral
transformer type with 6-8 volt lamp and shall be fitted with a glass color cap.
2.20 CONTROL CONSOLES AND VALVE AND GAUGE PANELS
2.20.1 Control Console Construction
The control console shall include a basic frame with metal panels fully custom-fabricated as specified, or may
consist of custom modules using standardized components where available to meet the dimensional and functional
characteristics indicated and specified. Unless otherwise indicated, the console shall be constructed of steel
meeting the requirements of NEMA ICS 6. Steel sheet shall conform to ASTM A 659/A 659M. Removable panels shall
be secured in place using captive, spring loaded, self-locking spring nuts and hardened sheet metal screws.
Screws and nuts shall be corrosion-resistant material or shall have corrosion-resistant protective coating.
Access panels shall be secured with spring loaded quarter turn fasteners with studs held captive in the removable
panel. The console shall be equipped with adequate louvered panels to ventilate the interior and dissipate the
heat generated within the console. Special equipment supports and guides shall be provided as required to support
the equipment and other components within the console. Unless otherwise specified, interior and exterior surfaces
shall be finished with one coat of primer and two coats of manufacturer's standard finish.
2.20.2 Valve and Gauge Panels Construction
Valve and gauge panels shall be constructed of steel plate thick enough to provide rigid support for the valves
and other components mounted thereon. All piping shall be terminated with bulkhead type connections in a position
convenient for the connection of external lines. Primer and finish shall be manufacturer's standard coating.
2.20.3 Nameplates and Instruction Plates
Nameplates shall be provided for each device on the control console, valve panels and gauge panels. Nameplates
shall clearly indicate the function of each device and, in the case of manually-operated controls, shall indicate
the condition established for each position of the control. Instruction plates shall clearly indicate the proper
procedures and sequences of operations to activate the system, to operate the system, and to secure the system
after completion of operation. Lettering on nameplates shall be machine-engraved on plastic laminate with white
characters on a black background. Instruction plates shall contain permanent black letters on a white background.
Instruction plates shall be mounted on a rigid backing and covered with clear, rigid plastic sheeting. Instruction
plates shall be mounted in a location easily visible to an operator stationed at the console or panel.
2.20.4 Security Provisions
Control consoles shall be constructed and installed to prevent unauthorized or accidental operation of the system.
[The main power control switch mounted on the control console shall be a key-operated type with provision for
removal of the key only when the switch is in the "OFF" position.] [The control console shall be provided with
a hinged cover with a key-operated lock arranged to automatically lock the cover in the closed position.]
2.20.5 Weather Protection
Control consoles and valve and gauge panels exposed to the weather or subjected to water or dirt in the atmosphere
shall be NEMA Type 4 for exterior [hazardous] [nonhazardous] application. Enclosures shall have hinged and latched
covers. Hinges shall be separable type to permit complete removal of the cover for maintenance. Hinges and
latches shall be constructed of corrosion-resistant steel or approved nonferrous metals.
2.21 TEMPORARY CORROSION PROTECTION
Unpainted metal surfaces shall be protected from corrosion during shipment, storage at the site, and during construction
operations so that the surfaces are free of corrosion until application of final field finish. The temporary
coating shall be completely removed and the surfaces properly prepared for final finishing as specified in Section
09 90 00 PAINTS AND COATINGS. Products, including pumps, reservoirs, cylinders, and similar assemblies, shall
not be provided unpainted or with temporary coating, but shall be factory finished as specified.
2.22 ELECTRIC MOTORS AND CONTROLS
NOTE: Where motor starters are provided in motor control centers, delete the
reference to motor starters.
Electric motor-driven equipment shall be provided complete with motors [motor starters] and controls. Electric
equipment and wiring is specified in [Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM.] [Section
33 70 02.00 10 ELECTRICAL DISTRIBUTION SYSTEM, UNDERGROUND.] [Section 33 71 01 OVERHEAD TRANSMISSION AND DISTRIBUTION.]
Electrical characteristics shall be as indicated or specified. [Motor starters shall be provided complete with
properly sized thermal overload protection and other appurtenances necessary for the motors specified.] Manual
or automatic control and protective or signal devices required for the operation, and any control wiring required
for controls and devices but not shown on the electrical drawings, shall be provided. Where two-speed or variable-speed
motors are indicated, solid-state variable speed controller may be provided to accomplish the speed function.
Each motor shall be sized large enough to drive the equipment at the specified capacity without exceeding the
nameplate rating of motor when operating at proper electrical system voltage.
PART 3 EXECUTION
3.1 EXAMINATION
After becoming familiar with all details of the work, verify dimensions in the field and advise the Contracting
Officer of any discrepancy before performing the work.
3.2 INSTALLATION
Installation of hydraulic components shall be in accordance with the manufacturer's written instructions and
under the direction of the hydraulics technician. Complete units or assemblies shall be installed without disassembly.
Necessary supports for all appurtenances, pumps, motors, heat exchangers and other equipment or components shall
be provided. Floor-mounted equipment shall be anchored to concrete pads by dowels set in the concrete. Shear
blocks may only be used where installation of dowels is completely impractical. Concrete for foundations shall
be as specified in Section 03 31 00.00 10 CAST-IN-PLACE STRUCTURAL CONCRETE. Drain lines shall be installed
from the reservoir to each component requiring a drain connection. All valves and other fluid control devices
shall be mounted as indicated. Mounting subplates shall be installed on rigid supporting surfaces in a manner
that will preclude imposition of forces on the piping and tubing other than those created by fluid pressure alone.
Shims shall be provided at locations required to permit proper adjustment, alignment, and position of system
components and assemblies. Components shall be marked to indicate pertinent operational requirements, warnings,
and limitations such as maximum allowable operating pressure, temperature, velocity, range of adjustment, flow
capacity, stroke, direction of flow, rotation or motion, safety precautions, and materials compatibility. The
markings shall be by stamping or embossing on the component or on an attached plate or tag which shall, barring
mutilation, remain affixed and legible for the life of the component.
3.2.1 Components and Subassemblies
Components shall be securely mounted to the supporting surface. Care shall be exercised that fastenings are
not overtightened to the extent that component bodies are distorted or damaged. Pivot type mountings shall be
carefully aligned to ensure free operation throughout the entire range of movement. Cylinders shall be carefully
aligned so that no side loads are imposed on the piston rod at any point in the full stroke. Subassemblies shall
be mounted and braced independently of the connecting lines.
3.2.2 Connections to Mechanisms
Pumps and motors shall be carefully aligned with the mechanisms to be operated and shall be shimmed as necessary
to eliminate angular and radial misalignment between the mating shafts. Shaft couplings which require lubrication
shall be lubricated at the time of installation. Pivot-type connections shall be lubricated at assembly.
3.2.3 Rigid Conductors
Hydraulic pipe and tubing shall be securely mounted and anchored to structural members. Supports and anchors
shall be located as indicated. Guards shall be provided at all locations where the structure does not provide
protection for the lines from damage due to movement of personnel and equipment. Seals shall not be removed
from pipe and tubing assemblies or from ports on components until the lines are ready for connection. Provisions,
including but not limited to providing portable screens and shelters, shall be taken to minimize the entrance
of abrasives, dirt, metal chips, and other foreign materials into the hydraulic system through open ends of lines
and ports of components.
3.2.4 Flexible Conductors
Flexible conductors shall be installed in accordance with the manufacturer's recommendations. Special care shall
be exercised to avoid imparting any twist in the conductors during tightening of fittings. Supports shall be
provided and located to prevent conductors from contacting and chafing against fixed members. Clamps and straps
used to support hoses shall be provided with soft resilient sleeves, linings or bushings to prevent cutting and
abrading of the hose. The routing of flexible hoses shall be arranged to preclude imparting a twist in the hose
due to relative motion between the components to which the hose is connected. The minimum bend radius of the
hose shall not be less than that recommended for the particular hose size and maximum system operating pressure.
Heat shields or insulating jackets shall be provided where hose passes close to heated surfaces.
3.2.5 Installation of Tubing
Tubing shall be cut square using tube cutters specifically designed for the material to be cut. The use of hacksaws
or other chip-producing equipment will not be permitted. Burrs shall be completely removed after the tubing
is cut and the inside diameter of the tube shall be chamfered slightly. After the cutting and deburring operations,
all metal fragments shall be removed from the tubing interior and from sealing surfaces. Tube benders designed
and recommended by the manufacturer shall be used for bending stainless steel tubing of the wall thicknesses
and sizes specified for the installation. Bends shall be accurately made to the proper angle so that fittings
align properly and mate without application of force or springing of the tube or fitting and alignment shall
be true enough so that threads may be engaged and hand turned not less than three turns. Bends shall be completely
free from wrinkling, and flattening shall not exceed 5 percent of the outside diameter. Tube benders shall be
provided with necessary radius blocks, slide blocks, and special close radius blocks, as required to adapt the
bending tools to the requirements of the work. Where necessary to ensure properly fabricated bends, internal
mandrels of proper diameter for the size and wall thickness of the tubing shall be used.
3.2.6 Test Connections
Test connections and test valves shall be provided at each location indicated. Unless otherwise indicated, all
test connections shall be 6.4 mm 1/4 inch size.
3.2.7 Welded Installation
Hydraulic pipe weldments shall be as indicated. Changes in direction of piping shall be made with welding fittings
only; mitering or notching pipe to form elbows and tees or other similar type construction will not be permitted.
Branch connection may be made with either welding tees or forged branch outlet fittings. Branch outlet fittings
shall be forged, flared for improvement of flow where attached to the run, and reinforced against external strains.
Beveling, alignment, heat treatment, and inspection of welds shall conform to ASME B31.1. Weld defects shall
be removed and repairs made to the weld, or the weld joints shall be entirely removed and rewelded at no additional
cost to the Government. After filler metal has been removed from its original package, it shall be protected
or stored so that its characteristics or welding properties are not adversely affected. Electrodes that have
been wetted or that have lost any of their coating shall not be used.
3.3 MANUFACTURERS' FIELD SERVICES
Services of a manufacturer's representative who is experienced in the installation, adjustment, and operation
of the equipment specified shall be provided. The representative shall supervise the installation, adjustment
and tests of equipment. Services of a hydraulics technician to coordinate and supervise the installation, adjustments,
tests, and field instructions for the hydraulic system shall be procured by the Contractor. The hydraulics technician
shall have at least 3 years of current experience in the installation and operation of similar systems and shall
be recommended by the system supplier or may be the manufacturer's representative.
3.4 FIELD TESTS AND CLEANING OF HYDRAULIC LINES
NOTE: If the hydraulic system is delivered as a self-contained packaged unit,
tested, sealed, and certified by the manufacturer, delete the second paragraph
under SD-06, Repair Requirements, under paragraph SUBMITTALS and also this paragraph
and its subparagraphs in their entirety.
Secure the services of a hydraulic engineer or technician, as approved by the Contracting Officer, for [_____]
working days to monitor the final cleaning and testing of the hydraulic system.
3.4.1 Proof Testing
NOTE: If the work involves modifications to existing hydraulic systems, delete
the brackets in the first sentence. Otherwise, delete the expression within
the brackets and the brackets.
All lines [including reinstalled existing lines], except component drain lines, shall be proof tested to not
less than 150 percent of design operating pressure. Component drain lines shall be proof tested to 150 percent
of the design working pressure or 690 kPa 100 psi, whichever is the greater. All welded, flanged, flared, and
threaded connections shall be carefully examined for leakage and all lines shall be inspected for evidence of
deflection caused by inadequate anchorage. The proof test medium shall be either the fluid approved for use
in the system or a flushing compound specifically approved for use by the manufacturer of the fluid approved
for use in the system. Proof test pressure shall be maintained long enough to permit thorough and complete inspection
but in no case less than 1 hour for each test.
3.4.2 Field Cleaning
NOTE: If the work involves modifications to existing hydraulic systems, delete
the brackets in the first sentence. Otherwise, delete the expression within
the brackets and the brackets.
The allowable limit of contamination in this paragraph is subject to the specific
project design requirements which may necessitate revision or expansion to cover
varying standards of acceptance. The amount and sizes of particles which any
given component can tolerate is a function of the clearances between moving
parts, the frequency and speed of operation, and the materials of construction.
Tolerances range from low pressure gear pumps which may give satisfactory performance
with dirt levels typically found in new fluid (SAE J1165 18/15) to servo control
valves which require oil eight times cleaner (SAE J1165 15/12). General guidelines
are as follows:
System Type Code Level
Low pressure - manual control 18/15 or better
Low to medium pressure -
electrohydraulic controls 17/14 or better
Systems with servo or proportional
control valves 17/14 or better
High pressure - servo controlled 15/12 or better
Hydraulic fluid power equipment is rated according to maximum pressure. Generally
low pressure is 0 to 4.1 MPa (0 to 600 psi), medium pressure to 21 MPa (3000
psi), and high pressure to 35 MPa (5000 psi).
Results of microscopic particle count in accordance with SAE ARP598 are reported
as the number of particles per milliliter greater than indicated sizes as ordinates
on a graph where particle size in microns is the abscissa. Segments of the
ordinate are assigned code levels and the code level for particle sizes greater
than 15 microns is reported as the numerator and the code level for particle
sizes greater than 5 microns is reported as the denominator in the pair of range
numbers in the ISO (International Organization for Standardization) Solid Contaminant
Code, as identified in SAE J1165. Higher code levels indicate higher particle
counts per milliliter. Example: 15/12 means a code level of 15 for particles
greater than 5 microns and a code level of 12 for particles greater than 15
microns. Filter manufacturing firms can be the source of information regarding
determination of contamination levels and analysis and have available portable
kits for more general detection of contamination.
After proof tests have been satisfactorily completed, field installed hydraulic lines [including reinstalled
existing lines] shall be cleaned in place. Submit a detailed field cleaning procedure for approval in accordance
with paragraph SUBMITTALS not less than [_____] days before start of cleaning operations. The procedure shall
include detailed description of equipment, materials, formulations of cleaning agents, solution temperatures,
duration of each phase of the cleaning operation, method of removal of cleaning agents, and method of drying
after cleaning. The procedure shall free the system of particles so that the contamination level shall be below
15/12 [_____] in accordance with SAE J1165. Collection of samples and conduct of tests shall be performed by
an approved independent testing laboratory selected by the Contractor. The samples shall be examined for particle
size and population count by the millipore or equivalent method in accordance with SAE ARP598. Tabulation of
particle size and population shall be in accordance with the size groupings in accordance with SAE J1165; and
to the extent possible, particles shall be visually identified as metallic or nonmetallic, magnetic or nonmagnetic,
and by color and composition. Fluid shall be circulating in the system at not less than system design fluid
operating velocity during withdrawal of the samples. Three 500 milliliter size samples shall be taken at random
locations in each flushing of the system. If any sample does not comply with the permissible contamination limits,
the system shall be recleaned and reinspected. Accessible interior portions of the system shall also be subjected
to visual and wipe tests and any evidence of contaminants exceeding allowable limits shall require recleaning
of the system.
3.4.3 Field Training
NOTE: The blank will be filled with the appropriate number of hours required
for giving instructions.
Provide a field training course for designated operating staff members. Training shall be provided for a total
period of [_____] hours of normal working time and shall start after the system is functionally complete but
prior to final acceptance tests. Field training shall cover items contained in the Operation and Maintenance
Manuals.
3.4.4 Hydraulic System Final Acceptance Tests
3.4.4.1 Preparation
NOTE: The requirement for preliminary tests by the Contractor before the final
acceptance tests may be deleted for those systems for which the Corps of Engineers
has the sole responsibility for acceptance of the system or for simple systems
which can be acceptance-tested in one working day and require only one inspector
to observe the test.
In preparation for the final acceptance tests, and after completion of installation, lubrication, and adjustment,
operate the hydraulic system to prove acceptability. Complete this test not less than 10 days before beneficial
occupancy. Conduct preliminary tests at minimum pressures and velocities until initial adjustments have been
proven safe for normal operation. Details of all operations shall be constantly monitored for signs of impending
trouble and corrections made as necessary to prevent damage to equipment. [A written statement that the hydraulic
system has been field tested and meets all operational requirements shall be furnished to the Contracting Officer
before scheduling the final acceptance tests.]
3.4.4.2 Conducting Final Acceptance Tests
At such time as the Contracting Officer may direct, conduct the following complete acceptance tests on the hydraulic
system for approval. All tests shall be conducted in the presence of the Contracting Officer. Each deficiency
or maladjustment disclosed by the tests shall be corrected immediately and the test repeated until satisfactory
results are obtained. No subsequent tests will be permitted until all preceding tests have been completed satisfactorily.
a. Initial Start-Up: The hydraulic reservoirs shall be inspected to ensure that fluid is at the proper
level. [It shall be verified that the fluid equalizing valve is fully open.] [The reservoir pressurization
system shall be inspected to ensure that all valves are open and that the pressure regulating valve is
adjusted to provide the specified pressure in the reservoirs.] [The accumulator precharge pressure shall
be inspected and adjusted to specified value.] The hydraulic pumps shall be started using the controls
at the control console. The operation of the pumps shall be inspected for proper operation and discharge
pressure. [The pressure compensator shall be adjusted as required.] [The pressure compensators shall
be adjusted to equalize the discharge pressures.] The discharge pressure of [the] [each] pump shall
be read and recorded. [The pressure relief valve shall be adjusted to limit system pressure to the specified
value.] [The unloading valve shall be adjusted to unload the pumps to the reservoir when the accumulator
has been charged to the specified pressure.] Hydraulic lines and components which are under pressure
shall be inspected for evidence of leakage and for evidence of distortion because of inadequate or improper
support. [Branch circuit pressure reducing valve and relief valve settings shall be inspected and adjusted
as required to obtain specified values.]
NOTE: The contents of this paragraph are dependent upon the size and complexity
of the systems covered by this specification. Complete testing of the entire
system may necessitate expansion by including additional appropriate paragraphs
if the system involves several subsystems which warrant individual testing.
b. Combined System Tests: Tests and inspections of [the hydraulic system] [each branch of the hydraulic
system] shall be performed concurrently with the testing specified under other sections which test the
mechanism operated by the hydraulic system. During each test operation hydraulic lines and devices shall
be inspected for leakage and for evidence of distortion due to inadequate or improper support. The pressure
in the supply and return lines for each direction of operation shall be read and recorded. Response
of components to operation of applicable controls [on the control console] shall be inspected to ensure
that all connections have been made properly. [Flow control valves shall be checked and adjusted as
required to conform to indicated operating time requirements.] [Sequence valves shall be inspected and
adjusted as required to obtain the indicated sequence of operation.] [Chokes in pilot circuits of pilot-operated
valves shall be adjusted to obtain smooth, shock-free operation.] [Restriction in externally piloted
counterbalance valves shall be adjusted to obtain smooth operation without vibration.]
NOTE: Edit the list as required.
c. Test Logs: Prepare and complete a test log showing in detail the results of the tests. Three copies
of the completed test log shall be delivered to the Contracting Officer not more than 48 hours after
completion of the tests. Prepare a complete and detailed tabulation showing values of pressures, flow
rates, and all adjustments recorded during final tests, adjustment, and calibration of the entire system.
During each test run, the following data and observations shall be recorded:
(1) Control operation
(2) Voltages
(3) Currents
(4) Hydraulic pressures
(5) Speeds and times
(6) Flow control valve settings
(7) Alignment and operating clearances
(8) Excessive vibration, by component
(9) Temperature of motors and hydraulic fluid
(10) Pertinent observations regarding such events as unusual sounds, malfunctions or difficulties
encountered, and adjustments required.
3.5 PAINTING AND COLOR CODING
3.5.1 Painting
All exposed exterior surfaces of assemblies and equipment except corrosion-resistant steel, synthetic rubber,
and plastic, shall be shop primed and coated as specified: Complete system, including color coding and piping,
shall be painted as specified in Section 09 90 00 PAINTS AND COATINGS. Insofar as practicable, the complete
coating system shall be applied to individual components and items before assembly to ensure complete coverage
and maximum protection against corrosion.
3.5.2 Pipe Color Code Marking
NOTE: Designer will coordinate color code marking with Section 09 90 00. Color
code marking for piping not listed in Table I of Section 09 90 00 will be added
to the table.
Color code marking of piping shall be as specified in Section 09 90 00 PAINTS AND COATINGS.
3.5.3 Field Touch-Up
Chips, scratches, and other damage to shop-applied painted surfaces shall be repainted in the field. Finish
field colors shall match those of marred finishes.