Cylinder_0001.pdf

Cylinder (Drawing Nos. R.652/2763):

1. Clean and inspect for discrepancies with drawings tolerances.

2. Machine to remove piston ring wear. Please provide maximum ID size allowable by design No maximum is identified.

a. Bore cylinder to 2 foot 4.000 inches ±0.003 inches This assumes the no material removal is required, damage in photos suggest otherwise. Boring to a larger diameter is allowed so long as the piston rings and piston are sized appropriately.

b. Hone cylinder bore to obtain final finish

Piston (Drawing No. 416-MD-35-107):

1. Clean and inspect for discrepancies with drawing tolerances.

2. Inspect piston bore, if out of tolerance, machine to insert sleeve using same material If original method of sleeve installation is to be assumed welding should be per ASME Section IV, all weld procedures and welders should be qualified to that code. Correct with interference fit. Finish as per drawing to 125 micro-inch. Please provide OEM Standard clearance of piston to Cylinder OEM cylinder bore of 28" plus/minus 0.003" and a piston size of 27.996. This clearance does not have to be maintained so long as the internal leakage is acceptable and the piston operation is smooth from full open to full closed (no binding or abnormal noises). To restore the piston to cylinder clearance, bronze sleeves or bands of phenolic material can be installed on the piston.

3. Clean and inspect grooves for piston rings.

a. If out of tolerance, machine to restore square shoulders and finish as per OEM drawings with COR approval. If oversized, welding is required to perform this work please reference above statement , line 2 Correct

4. Fit piston with three new piston rings (Item 9), oversize rings as may be required

3.03 SHOP TESTING

A. Hydrostatic test as noted on OEM Drawing No. R652/2763 using pre-heated ISO 68 Hydraulic Oil.

B. Record all pressures, time duration, and leakage point and rates for the servomotor testing.

C. Leak test:

1. Pressurize to 450 psi.

a. Maintain pressure long enough to calculate an accurate flowrate through the piston rings.

b. Perform on servomotors in both open and closed positions.

1) Piston and rod fully extended and retracted.

2. Internal leakage:

a. Record the internal leakage. Please provide original leakage from OEM No OEM standard is given.

Reclamation empirical data suggests acceptable internal leakage range up to 170 oz in a period of 30 minutes for similar sized servomotors tested at 450 psi.

3. External leakage:

a. No leakage is allowed.

b. Verify there is no leakage through the packing, head gasket, plug, check valve and any other ports or mating surfaces on the servomotor.

D. Stroke:

1. Measure the full available servomotor stroke; piston movement from fully open to fully closed positions.

2. Record position of stroke limiter.

* Industry standard would require some level of NDE to the pressure boundary components such as the cylinder and heads, is this assumed or not required ? This was assumed. Anyone preforming NDE should be level II certified.

* There is no mention of blasting or recoating, the existing coatings will be damage during the refurbishment. Additionally, if NDE is required existing coating will need to be removed. Any coating removal needed to perform NDE is acceptable. Reclamation plans to apply new coatings inhouse before re-installing the servomotors.