Navigation Lock Hydraulic Cylinder Tech Specs .docx

TECHNICAL SPECIFICATIONS

Navigation Lock Hydraulic Cylinders

Intent

The following specifications pertain to the cost to provide three (3) new hydraulic cylinders for use at Little Goose Lock and Dam, Dayton, WA.

Scope

The successful offeror shall be required to provide three (3) new hydraulic cylinders with intermediate trunnion mounts, and one (1) rebuild kit for the new cylinders to be used on our navigation lock miter gates and conform to the specifications listed in section 3.0 titled specifications.

Specifications

0. HYDRAULIC CYLINDERS

The three (3) hydraulic cylinders shall be double acting, non-cushioned, and intermediate trunnion mounted. The Cylinder bore and stroke shall be as indicated on the attached drawings. The operating temperature range for these cylinders will be -20℉ to 150℉. The assumed duty cycle shall be 15 cycles per day. Cylinder design shall allow for disassembly with parts identified and numbered. The cylinders shall be designed to withstand 2660 psi with a minimum factor of safety of 3 based on the ultimate strength of the material or a factor of safety of 2 based on yield strength of the material. The operating pressure of the cylinders will be 2000 psi. Welding shall be in accordance with ASME BPVC Section VIII Division 2 or as indicated. Bolts shall conform to ASTM A325, ASTM A354, ASTM A574, or as indicated. Attached are drawings that include dimensions and specifications for the individual components of the hydraulic cylinders. The new cylinders shall have rod wipers, rod seals, and rod bearings of materials to prevent metal-to-metal contact with the rod. The new cylinders shall have piston seals and piston wear rings of materials to prevent metal-to-metal contact with the cylinder Bore. The hydraulic cylinder assembly shall be compatible with environmentally acceptable lubricants such as polyalkylene glycol (PAG) based fluids. The cylinders shall be painted with the manufacturer’s standard.

0. TRUNNION MOUNTS

Three trunnion mounts shall be fabricated per drawing N-102.575 sheet 3. One trunnion mount per cylinder shall be mounted on each cylinder in its designated location and orientation per drawing N-102.575 sheet 1. The trunnion mounts shall be painted with the same coating as the hydraulic cylinder.

0. REBUILD KIT

One (1) rebuild kit for the new cylinders shall be included with the procurement of the hydraulic cylinders. The rebuild kit shall include one (1) new gland, two (2) piston wear rings, two (2) piston seals, one (1) rod wear ring, one (1) rod lip seal, (1) rod wiper seal, one (1) piston O-ring, and one (1) gland O-ring. All components of the rebuild kit shall be the same specs as what is installed in the new hydraulic cylinders.

4.0 SUBMITTALS

4.1 SUBMITTALS AT TIME OF CONTRACT AWARD

If departures from the contract drawings are deemed necessary by the Contractor, details of such departures, including changes in related portions and reasons therefore, shall be submitted for approval within five (5) calendar days after date of contract award.

4.2 SUBMITTALS AT TIME OF DELIVERY OF HYDRAULIC CYLINDERS

Three copies of the manufacture’s catalog data, descriptive literature, and detailed shop drawings shall be submitted with the delivery of the new cylinders and the rebuild kit. Shop drawings shall include a cross section drawing of the cylinder with parts identified and listed with corresponding part numbers.

5.0 MATERIALS

Where items are referred to as “similar and equal to” a particular manufacturer’s product, such references have been made merely as a convenient method of indicating the type of material or equipment required, with no intention of asserting superiority thereof. The standard product of any reputable manufacturer regularly engaged in the commercial production of the type and quality of material or equipment referred to will not be excluded on the basis of minor differences, provided essential requirements of the specifications relative to materials, capacity, and performance are met. Chrome plating shall conform to ASTM B 177. Material used shall be fabricated from the finest selected quality materials to provide zero leakage to the outside of the cylinder and near zero leakage past the piston seals.

6.0 HYDRAULIC FLUID

The hydraulic fluid to be used during shop testing and to fill the cylinders before shipment shall be Rando HD ISO 46. Fluid shall be filtered through a 10-micron filter before it is added to the system.

7.0 CYLINDER TESTS

Each cylinder shall be filled with the specified hydraulic fluid filtered to 10 microns, taking care to exclude all air. Each cylinder shall then be hydrostatically tested at 2660 psi for a minimum of 4 hours. With the cylinder fully retracted and under pressure, the cylinder shall be checked for leakage past the rod and piston seals. The cylinder shall then be extended and observed for smooth, even travel. With the cylinder fully extended and under pressure, the cylinder shall be checked for leakage past the rod and piston seals. Any leakage past the rod seals shall be cause for rejection. Any operation problems or source of leakage to the outside of the cylinder will be cause for rejection and cylinder shall be repaired and retested. More than one ounce of fluid per hour past the piston seals will be cause for rejection. Three copies of a complete test report shall be submitted with the cylinder delivery.

8.0 SHOP ASSEMBLY AND TESTING

The new hydraulic cylinders shall be completely shop assembled and tested, insofar as possible, using temporary piping and wiring to determine the correctness of fabrication and the matching of component parts to ensure acceptable operation. The Government reserves the right to witness all testing efforts, provide a minimum 7-days’ notice prior to conducting any tests.

Upon satisfactory completion of the tests, the cylinders may be delivered to the project.

9.0 CLEANING

Extreme caution shall be taken during shop assembly to avoid inclusion of foreign materials into the equipment. The interior of the piping, including piston rods, shall be cleaned with lint free cloths and flushed with 150℉ oil at a minimum velocity of 15 fps which has passed through a 10-micron filter. The cleaning procedure shall clean the system of particles so that the contamination level is below 17/14 in accordance with SAE J1165. The manufacturer shall take three 500 milliliter samples at random locations according to ANSI B93.19. Particle counting on each sample shall be performed in accordance with SAE ARP 598B by an approved independent test laboratory. Submit name, address, telephone number and email of proposed testing laboratory. Water content of each sample shall be below 200 ppm. If any sample does not comply with the permissible contamination limits, the system shall be recleaned and reinspected.

10.0 Shipment and Delivery

All items shall be delivered FOB Destination to Little Goose Dam within 20 weeks of award. Packing, crating, cradles, etc., necessary to ensure safe shipment are the responsibility of the contractor and shall become the property of the government upon delivery of the cylinders at Little Goose Lock and Dam. The hydraulic cylinders shall be filled with the specified hydraulic fluid. Any loss or damage during shipment, including damage to the painted surfaces, will be considered the responsibility of the contractor, and shall be replaced or repaired by the contractor.

The contractor shall make prior arrangements with the Government Personnel at site to deliver and unload the equipment.

Normal working hours at Little Goose Dam is 6:30 a.m. to 5:00 p.m., Monday through Thursday. The delivery shall arrive between 7:00 a.m. and 3:00 p.m. during normal working days. This is to allow for unloading and inspection. The delivery shall be made to the south side of the dam. Delivery address is as follows:

US Army Corps of Engineers Little Goose Lock and Dam 1001 Little Goose Dam Road Dayton, Washington 99328

The technical point of contact at Little Goose Dam is Jeremy Nichols, Mechanical Engineer, 509-404-3269.

11.0 WARRENTY

The new hydraulic cylinders shall be covered by a minimum one-year warranty on workmanship.

All shipments shall be delivered to:

US Army Corps of Engineers Attn: Jeremy Nichols 1001 Little Goose Dam Road Dayton, WA 99328

Ph. (509) 404-3269