SECTION_35_20_17_-_Gate_Hydraulic_Operating_Unit_R1_0004.pdf

BUREAU OF INDIAN AFFAIRS OGLALA DAM SPILLWAY AND OUTLET WORKS

OGLALA DAM SPILLWAY AND OUTLET WORKS SECTION 35 20 17

JUNE 2023 GATE HYDRAULIC OPERATING UNIT

FOR BID REV 1 PAGE 1 OF 8

SECTION 35 20 17

GATE HYDRAULIC OPERATING UNIT

PART 1 GENERAL

1.01 SCOPE OF WORK

A. This Section specifies the requirements for furnishing and installing the complete Hydraulic Operating Unit to operate the outlet works stainless steel slide gate within the operating conditions of this Specification. The Hydraulic Operating Unit includes but is not limited to: Hydraulic Power Control System, hydraulic lines and couplings, operating controls, fasteners, and accessories.

1.02 REFERENCES

A. American Water Works Association (AWWA)

1. AWWA C540 Standard for Power-Actuating Devices for Valves and Sluice Gates

B. American Welding Society (AWS)

1. AWS D1.1 Structural Welding Code Steel

C. American National Standards Institute (ANSI)

1. ANSI B93.10 Static Pressure Rating Methods of Square Head Fluid Power Cylinders

2. ANSI B93.15 Mounting Dimensions for Square Head Industrial Fluid Power Cylinders

1.03 DEFINITIONS

A. Hydraulic Power Control System (HPCS): A skid-mounted system to provide hydraulic power for the Hydraulic Operating Unit to control the movement of the hydraulic gate.

Includes, but is not limited to, hydraulic pumps and motors, manual pumps, position indicator, hydraulic reservoirs, valves, accumulators, hydraulic fluid, and other components necessary to provide and control hydraulic power.

B. Gate Operating Controls: Gate position controls consisting of manual pushbutton controllers, NEMA control panel enclosure and other accessories necessary for gate position operation and control.

BUREAU OF INDIAN AFFAIRS SECTION 35 20 17

FOR BID REV 1 PAGE 2 OF 8

1.04 SUBMITTALS

A. Shop Drawings

1. Submit Gate Hydraulic Operating Unit Shop Drawing for approval by the BIA Representative including the following:

a. Manufacturer name, product name, model, and/or number.

b. Complete motor nameplate data.

c. Power and control wiring diagrams.

d. For Fabricated Items: Complete drawings showing details of fabrication and assembly and demonstrating compliance with Specification requirements.

Include all dimensions, tolerances, sizes, finishes, fasteners, welds, and materials of construction. Identify all field connections. Reference all construction materials by ASTM designations and grades.

e. For Standard Manufactured Items: Manufacturer’s catalog work sheets showing illustrated cuts of items to be furnished and demonstrating compliance with Specification requirements. Include scale details, dimensions, fasteners, finishes, and materials of construction. Reference all construction materials by ASTM designations and grades.

f. Hydraulic Operating Unit Design Data:

1) Coordinate design and installation of the Hydraulic Operating Unit with designs and installation of hydraulically operated outlet works gate in accordance with Section 35 22 00 – Stainless Steel Slide Gate.

2) Driver medium pressure rating and volume per stroke for the gate actuation cylinder.

3) Include hydraulic schematics of Hydraulic Operating Unit.

g. Detailed drawings indicating locations and complete assembly details for hydraulic lines, Hydraulic Power Control System, and Gate Operating Control Panels and relationships to adjoining Work; include details for connections to water control gate hydraulic actuator and attachments to structures.

Reproduction of Contract Documents will not be accepted for this purpose.

Verify all dimensions to ensure proper fit of all items.

h. Sign and seal by a registered Professional Engineer.

2. Submit a Gate Hydraulic Operating Unit Work Plan for approval by the BIA Representative including the following:

a. Complete written installation, operation, and maintenance instructions including provisions and procedures for coordination of installation of water control gates.

b. Procedures for shop and field adjustments and field testing.

c. Installation and testing sequence and schedule.

B. Administrative

1. Manufacturer’s Certificates of Proper Installation.

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2. Operation and maintenance instructions.

3. Checklists for shop and field testing.

C. Quality Control

1. Certificate(s) of compliance with applicable AWWA standards.

2. Manufacturer’s Certificate of Compliance:

a. Hydraulic Operating Unit.

3. Certified results of shop and field testing: including measured clearances and tolerances results of all tests, and adjustments, repairs or replacements necessary to meet Specification requirements.

1.05 QUALITY ASSURANCE

A. Inspection of Hydraulic Operating Unit Manufacture/Fabrication: COR and BIA Representative reserve the right to inspect Hydraulic Operating Unit manufacture/fabrication facilities before and during manufacture/fabrication of products for inclusion in the Work.

1.06 SEQUENCING AND SCHEDULING

A. Notify BIA Representative in Writing:

1. At least 14 days prior to start of manufacture/fabrication of the Hydraulic Operating Unit components.

2. At least 5 days prior to start of:

a. Shop coating.

b. Shop assembly, inspection, and testing.

c. Field Testing.

1.07 WARRANTY

A. Warrant materials and installation for a minimum period of 5 years after the date of COR’s final acceptance of Work.

PART 2 PRODUCTS

2.01 HYDRAULIC OPERATING UNIT

A. General:

1. Oil-filled hydraulic motor operating unit system suitable for the range of temperatures at the site.

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2. Design for water control gate loading conditions (including, but not limited to, gate operating and design loads) provided by water control gate manufacturer and detailed in Section 35 22 00 – Stainless Steel Slide Gate.

3. Capable of maintaining the gate in any position from fully open to fully closed, without drift.

4. Safe, reliable and smooth operation, without binding, vibration, noise or heat.

5. Conform to AWWA C540, with additional requirements of these Specifications.

6. Gate has rising stem design.

7. Electrical controls shall be factory furnished in a NEMA 1 rated electrical enclosure, for mounting in the outlet works instrument and control panel.

8. The Drawings indicate the general concept, arrangement and requirements of the Hydraulic Operating Unit, and are not intended to define or represent detailed design of equipment to be furnished. The Hydraulic Operating Unit manufacturer/fabricator is responsible for complete design of the required hydraulic equipment. The Hydraulic Operating Unit manufacturer/fabricator shall also determine if the internal dimensions for the Gate Hydraulics Vault are adequate for the proposed equipment.

B. Operating Conditions:

1. Continuous operation with gate in any position between closed and fully with the operating heads in accordance with Section 35 22 00 – Stainless Steel Slide Gate.

2. Unwedging, unseating, or cracking gate open under maximum unbalanced seating head conditions.

3. Raising gate under balanced head or maximum unbalanced seating head conditions.

4. Closing gate under balanced head or maximum unbalanced seating head conditions.

5. Gate in fully closed position under maximum unbalanced seating head conditions.

C. Design Loads:

1. Obtain required design loads and actuator requirements from water control gate manufacturer. At a minimum, include the following three maximum operating conditions required to fully open or close the gate: (1) instantaneous force to unwedge, unseat, or crack open the gate from a fully closed position; (2) running force required after unseating the gate to lift the gate into the fully opened position; and (3) the closing force required to fully close the gate considering hydraulic pulldown of the gate.

D. Hydraulic Power Control System (HPCS):

1. Hydraulic fluid system of sufficient size and capacity to operate the gate hydraulic cylinder for the specified range of operating requirements.

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2. Skid-mounted and arranged to facilitate adjustment, operation and maintenance of the unit without removal from the outlet works Gate Control Vault. Provide permanently installed lifting eyes to facilitate the handling of the unit.

3. Operating Speed: Limit operating speed so that the time to fully open or close the gate is greater than 4 minutes.

4. Hydraulic Fluid: Non-petroleum-based biodegradable or “food grade” hydraulic fluid, compatible with drinking water standards for raw water.

5. Reservoir:

a. Designed and constructed to minimize entry of foreign matter including water.

b. Volume at least 1.25 times the total return oil volume required for the gate.

c. Equipped with a fluid level indicator with markings to show high and low levels and a float switch. The fluid level shall be visible in the sight gage throughout the normal operating cycle. The float switch shall be adjusted to detect the oil level at 80% of tank capacity.

d. Stainless steel construction.

e. Provide a baffle between the intake and return lines to facilitate separation of air and foreign matter from the hydraulic fluid.

f. One suction filter and one pressure filter shall be provided for oil pump and control valve protection. The suction filter shall be equipped with a 25-micron filter element, with an internal bypass, clogging switch, and a visual servicing indicator. The pressure filter shall be equipped with a 10-micron filter element, with an internal bypass, clogging switch, and a visual servicing indicator. The oil filters shall use replaceable elements, and six spare elements shall be furnished for each filter. The clogging switches shall have one Form C contact rated 120 volts AC, 5 amperes.

6. Motor:

a. Sufficient capacity to open and close the gate against all anticipated operating conditions when the voltage is 10 percent above or below the nominal voltage.

b. The electric motor shall be totally enclosed, and fan cooled, with cast iron frames, providing the necessary horsepower to operate the hydraulic pump at the maximum pressure required without exceeding the nameplate rating. The motor shall be operated on 240 volt, 60 hertz, single-phase alternating current, at an altitude of 3,000 feet, and a temperature range of -30 to110 degrees F.

7. Electrical Controls:

a. Electrical power controls, operating devices, and monitoring devices required on the HPCS shall be factory wired in a NEMA 1-rated enclosure.

E. Hydraulic Lines:

1. Sufficient size to prevent cavitation or starvation and undue temperature variations or turbulence.

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2. Hydraulic lines must be stainless steel with sufficient pressure rating to withstand 2 times the design operating pressure of the hydraulic system.

3. Provide a redundant set of hydraulic lines with cross over and isolation ball valves located near the gate cylinder and protected under the stainless steel plate that can be utilized in the event of damage, clogging or failure of the primary hydraulic lines.

F. Gate Operating Controls:

1. Provide independent operation from the outlet works instrumentation and control cabinet located within the control building. From this location it shall be possible to open, close, or stop movement of the gate.

2. Gate Controls: Provide a 3-position selector switch with MANUAL, AUTO, and OFF positions to select the mode of operation desired. Provide OPEN, CLOSE, and STOP pushbuttons with seal-in contact so that the pushbuttons do not have to be continually pressed for gate operation.

a. MANUAL mode allows operation of the gate using push buttons and ignores any automatic shutdown features.

b. AUTO mode allows the operator to set the desired gate position and the system moves the gate to the position

3. Instrumentation: Provide a low oil-level sensor for remote indication of low oil level, a high oil temperature sensor for remote sensing of high oil temperature, and a low pressure sensor for remote sensing of oil pressure less than 500 psi when the hydraulic system is operating.

4. Coordinate compatibility of the LVDT actuator position transmitter with the gate actuator manufacturer and provide a position display at the HPCS to allow adjustments and means of setting a position target and viewing the results.

5. A pressure switch shall be provided to shut off the hydraulic power unit at each end of travel of the slide gate. The pressure switch shall be set approximately 300 psi higher than the calculated operating pressure required for operation of the slide gates, to account for hydraulic losses in the power unit and piping. The pressure switch shall be furnished with a minimum of two contacts, rated 120 volts AC, 5 amperes.

6. A pressure relief valve shall be provided to limit the operating pressure in the control system to the maximum allowable operating pressure of the system.

7. Two counterbalanced valves or pilot-operated check valves shall be provided, one in each hydraulic line to the bottom port of each hydraulic cylinder, so that the gates will not close by gravity or flow-induced down-pull, unless hydraulic pressure is applied to the closing side of the cylinders.

2.02 SPARE PARTS

A. Provide spare parts as recommended by manufacturer for 5 years operation for each type and size equipment. Provide COR with an itemized list of the spare parts.

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2.03 SPECIAL TOOLS

A. Provide all special tools required for maintenance, disassembly, and assembly of the equipment. Provide COR with an itemized list of all special tools.

2.04 SOURCE QUALITY CONTROL

A. Hydraulic Operating Unit Shop Testing and Assembly:

1. In accordance with Proof-of-Design Tests, Section 6.2, of AWWA C540.

2. Perform any adjustments and/or repair or replace any components necessary to conform to approved shop drawings and meet Specification requirements.

3. A completed, dated, and signed copy of the detailed test procedure shall be shipped with the Hydraulic Operating Unit for verification of start-up settings.

PART 3 EXECUTION

3.01 GENERAL

A. Store unit and materials at the site in a suitable location protected from weather, corrosion, theft, vandalism, or other damage.

B. Do not store unit or materials directly on any ground surface.

C. Install Hydraulic Operating Unit in accordance with manufacturer’s written instructions.

D. Lubricate and grease in accordance with manufacturer’s instructions, provide manufacturer's recommended lubricants.

E. Arrange gate controls and HPCS to facilitate convenient gate operation. Provide stainless steel table, skid or shelving to raise the HPCS to a convenient operating level.

F. Do not use equipment that will damage components, paint or coatings. Repair damaged paint or coatings in accordance with the paint or coating manufacturer’s instructions.

G. After the initial fill, CONTRACTOR to flush the hydraulic system and filter the hydraulic oil prior to refilling. Internal filters shall be inspected prior to final fill. Clean/replace fouled filters as necessary.

3.02 FIELD TESTING

A. Perform at such a time as the BIA Representative determines that reservoir water levels are adequate to perform required tests; but within 5 years after the date of COR’s final acceptance of the Work. COR shall retain the right to operate equipment during interim period.

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B. Perform field testing in the presence of BIA Representative. Conform to approve test procedures and manufacturer’s written instructions.

C. In accordance with Performance Tests, Section 6.3, of AWWA C540.

D. Perform any adjustments and/or repair or replace any components necessary to conform to approved shop drawings and meet Specification requirements.

3.03 MANUFACTURER’S SERVICES

A. Provide for the following items of work:

1. Hydraulic actuator cylinders.

2. Hydraulic Power Control System.

3. Hydraulic Lines.

4. Gate Operating Controls.

B. Provide manufacturer’s representative on site to:

1. Oversee installation of the gate operating controls (LVDT position indicator, etc.) at the time of its installation.

2. Guide and supervise testing.

3. Guide and supervise any adjustments or corrections.

4. Certify that the Hydraulic Operating Unit has been installed in accordance with manufacturer recommendations and meets Specification requirements.

5. Train COR’s personnel in the operation and maintenance of equipment. The manufacturer’s representative shall instruct the COR’s personnel in operation of the Hydraulic Operating Unit for the project.

C. Coordinate so that testing and training for gates and actuators occur at the same time.

END OF SECTION