Section 11285 - Outlet Works Gates.pdf

OUTLET WORKS GATES – 11285

95% Submittal – 1/03/2017

SECTION 11285

OUTLET WORKS GATES

PART 1 – GENERAL

1.1 SECTION INCLUDES

A. Furnishing and installing one 66-inch-diameter flange back sluice gate, hydraulic gate operator, and accessories to be installed in the intake structure as shown on the Drawings. This sluice gate is designated as the Guard Gate in the Drawings and in these specifications.

B. Furnishing and installing one 48-inch-wide by x 72-inch-high rectangular sluice gate, hydraulic gate operator, and accessories to be installed in the gate tower as shown on the Drawings. This sluice gate is designated as the Control Gate in the Drawings and in these specifications.

C. Furnishing and installing one 18-inch-diameter sluice gate, hydraulic gate operator, and accessories to be installed in the gate tower as shown on the Drawings. This sluice gate is designated as the Low-flow Gate in the Drawings and in these specifications.

D. Furnishing and installing all hydraulic lines for each sluice gate, Hydraulic Power Unit (HPU), control panel and accessories in the gate house.

1.2 RESPONSIBILITIES

A. The sluice gate manufacturer is responsible for the fabrication, shop testing, field testing, and delivery of the sluice gates, actuators, HPU, hydraulic lines, and accessories in accordance with the Part 1, Part 2, and Paragraph 3.B of this Specification Section and applicable Drawings.

B. The construction Contractor is responsible for installing the sluice gates, actuators, HPU, Hydraulic Lines, and accessories in accordance with Part 1 and Part 3 of this Specification Section the Drawings. The Contractor shall be responsible for unloading and properly storing everything delivered by the gate manufacturer in accordance with these Specifications. The Contractor is responsible for repairing any damage to the sluice gates, hydraulic operators, HPU, hydraulic lines and accessories that occurs during or after the unloading process at the Project Site. Repairs to the sluice gates, hydraulic operators, HPU, hydraulic lines and accessories shall be completed by the Contractor to the Engineer’s satisfaction and at no additional cost to the Owner.

C. The Owner will pay the gate manufacturer after the shop testing is accepted as described in Paragraph 2.12 and all of the components described in this Specification Section are delivered to the Project Site in an acceptable condition.

D. The Owner will pay the Contractor for installation of the sluice gates, actuators, HPU, and hydraulic lines in accordance with Specification Section 01025: Measurement and Payment.

1.3 DELIVERY SCHEDULE

A. The Sluice Gate Submittal shall be provided to the Engineer by the sluice gate manufacturer no later than 21 days after the Owner issues the Notice-to-Proceed.

B. The sluice gates, actuators, HPU, hydraulic lines, and accessories shall be delivered to the Project Site no later than July 17, 2017. Liquidated damages will be assessed to the sluice gate manufacturer by the Owner for each calendar day that the delivery is late.

1.4 SUBMITTALS

A. The sluice gate submittal shall be submitted by the sluice gate manufacturer to the Engineer in accordance with Section 01300: Submittals. As a minimum, the sluice gate submittals shall include:

1. Certificate of compliance with applicable ASTM, AWWA, ANSI or

SAE standards.

2. Dimensional shop drawings for each gate and wall thimble.

3. The shop drawings shall clearly indicate the material and coatings for each component of the gate and operator.

4. Manufacturer’s catalog data and literature for the gates, stems, and other appurtenances.

5. Design calculations for the sluice gates and hydraulic operators.

6. Manufacturer’s installation instructions and connection details.

7. Manufacturer’s operation and maintenance manuals for the sluice gates, actuators, HPU, and controls.

8. HPU dimensions, manufacturer’s catalog data, installation instructions, hydraulic circuit diagram, electrical power requirements, control panel equipment arrangement and wiring diagram.

9. Hydraulic cylinder and lines, dimensions, details, and installation instructions.

10. Details of insulated flanges and bolts to isolate dissimilar metals.

1.5 REFERENCES

A. AWWA C560 – Cast-Iron Slide Gates B. AWWA C509 (latest revision) – AWWA Standard for Resilient Seated Gate

Valves C. ASTM A126 – Gray Iron Castings for Valves, Flanges, and Pipe Fittings D. ASTM A276 – Stainless Steel Bars and Shapes E. ASTM A312 – Seamless, Welded, and Cold Worked Austenitic Stainless

Steel Pipes F. ASTM B98 – Copper-Silicon Alloy Rod, Bar, and Shapes G. ASTM B584 – Copper Alloy Sand Castings for General Applications H. ASTM F593 – Stainless Steel Bolts, Hex Cap Screws, and Studs I. ASTM F594 – Stainless Steel Nuts J. ASTM D2000 – Standard Classification System for Rubber Products K. AWWA C540 – AWWA Standard for Power-Actuated Devices for Valves and Slide Gates L. ANSI B93.10 C540 – Static Pressure Rating Methods of Square Head Fluid

Power Cylinders.

M. SAE J517 – SAE Standard Specification for Hydraulic Hose

PART 2 - PRODUCTS

2.1 GENERAL

A. The sluice gates and accessories shall be provided by one manufacturer.

The manufacturer shall be one of the following: Hydro Gate Corporation;

Rodney Hunt Company; Waterman Industries; or approved equivalent.

B. Sluice gates and accessories shall comply with AWWA C560.

C. Sluice gates shall be provided with hydraulic actuators.

D. A single hydraulic power unit (HPU) capable of actuating all three sluice gates and a control panel shall be provided to control all three gates.

E. The new Low-Flow Gate shall be mounted on the existing flange as shown on the Drawings. The Contractor shall verify with the gate manufacturer that the bolt holes in the gate frame will match the bolt holes in the existing flange.

F. The Guard Gate shall be installed underwater by divers and will attach to an AWWA Class D Flange as shown on Drawing S6.

G. The new Control Gate shall be mounted on the Type E wall thimble provided by the gate manufacturer that will be cast into the bottom of the gate tower.

2.2 DESIGN HEADS FOR SLUICE GATES

A. The 66-inch-diameter guard gate shall be designed for a minimum seating head of 105 feet.

B. The 48-inch by 72-inch Control Gate shall be designed for a minimum seating head of 105 feet. The design of this gate should include the increase in water pressure for the earthquake load from Westergards formula.

C. The 18-inch-diameter Low-flow Gate shall be designed for a minimum seating head of 35 feet.

2.3 SLUICE GATE MATERIALS

A. Materials of construction shall be as listed in AWWA C560, except as described below.

B. The frame, slide and wall thimble shall be constructed of cast iron meeting the requirements of ASTM A126, Class B.

C. The wedges, wedge blocks, lift nut and stem block shall be constructed of bronze meeting the requirements of ASTM B584, Alloy C862.

D. The seating faces and guide liners shall be constructed of silicon bronze meeting the requirements of ASTM B-98, Alloy C651.

E. The stems and stem couplings shall be constructed of stainless steel meeting the requirements of ASTM A276, Type 304.

F. The fasteners shall be constructed of stainless steel meeting the requirements of ASTM F593/F594, Alloy Group 2.

G. The flush bottom seal shall be Neoprene, ASTM D2000, 60 Durometer, with a stainless steel ASTM A276, Type 316 retainer bar.

2.4 SLUICE GATE FRAMES AND GUIDES

A. The gate frame and guides shall be of one-piece construction.

B. Guide grooves shall be machined on all contact faces and shall be of such length as to support at least one-half (½) of the slide when it is in the full open position. Faces for mounting of wedging devices shall be fully machined.

C. Frames shall be flanged-back for mounting on wall thimbles or flanges as noted on the drawings. The frame shall be fully machined and drilled to match the wall thimble or flange as noted on the drawings.

D. Corrosion-resistant seating faces shall be mounted around the perimeter of the slide and frame. When the slide is in the fully closed position and wedged in position against the frame, maximum clearance between seating faces shall not exceed 0.004 inch.

2.5 SLUICE GATE WEDGES

A. Each gate shall be provided with a sufficient number of wedges to provide a practical degree of water-tightness.

B. Wedges shall be fully adjustable and keyed to prevent any lateral rotation.

C. All contact faces of wedges and wedge blocks shall be precision-finished with 63 micro-inch finish or better.

2.6 WALL THIMBLE FOR CONTROL GATE

A. Wall thimble for the Control Gate shall be E-type with rectangular front flanges and rectangular openings and conforming to AWWA C560.

B. The front face (upstream) of the wall thimble shall be machined and holes drilled and tapped for attaching the control gate with corrosion-resistant metal studs.

C. The vertical centerline shall be clearly marked at top and bottom to permit alignment of the front face in the vertical plane.

2.7 STEMS

A. All gates shall be equipped with rising stems, which will be connected by the gate manufacture to the hydraulic gate actuator.

B. Gate stems shall be sized in accordance with the manufacturer’s recommendations and shall be sized to withstand the axial compressive and tensile forces created during gate operation under the maximum unbalanced heads and to transmit in compression at least two times the rated output of the lift when a maximum hydraulic operating pressure of two-thousand-two-hundred pounds-per -square-inch (2200 PSI) is applied to the actuator system.

2.8 HYDRAULIC GATE OPERATORS

A. All three sluice gates shall be equipped with hydraulic gate operators which shall be controlled by a single hydraulic power unit located in the gate house as shown on the Drawings. The hydraulic gate operators shall be capable of maintaining the gate in any position from fully open to fully closed, without drift.

B. Hydraulic operators shall be sized to handle the full range of operating conditions and gates loads as calculated by the sluice gate manufacturer.

C. Hydraulic cylinders shall be heavy-duty, rated for 3,000 psi or greater working pressure, with minimum design burst pressure of at least 9,000 psi.

Hydraulic cylinders shall be designed and manufactured to National Fluid Power Association (NFPA) standards.

D. Dry contact limit switches and 4-20mA analog position indicators shall be provided on the control gate and low-flow gate hydraulic cylinders and wired for instantaneous indication and digital readout on the HPU gate control panel in the gate house. Limit switches only shall be provided on the guard gate hydraulic cylinder and wired for instantaneous indication on the HPU control panel in the gate house.

E. Position indicators shall be linear displacement, absolute, non-contact, magnetostrictive transducers. The transducers shall be furnished with ¾-inch watertight electrical connections. The sensor mechanical package shall be mounted inside the hydraulic cylinder, and the sensor electronics shall be mounted outside of the hydraulic cylinder. The position sensors shall be furnished with integral RG Type connectors and mating plugs, and watertight seal. The linear displacement position transducers shall meet the following requirements:

1. Type Magnetostrictive Displacement

2. Analog Output 4 to 20 mA, 1200 Ohm load

3. Resolution Infinite

4. Linearity = or – 0.02 % or -0.05 mm

5. Repeatability Same as resolution

6. Operating Current 24 Volts D.C.

7. Temperature Range -30 to 100 degrees Fahrenheit

F. Hydraulic lines shall be provided with necessary fittings and bends to be installed as shown on the Drawings from the gate house to the three hydraulic gate operators. All hydraulic lines shall be fitted with dual valve connections and valving to facilitate connection to the hydraulic gate operators underwater without hydraulic oil leakage or water infiltration into the hydraulic system.

G. Hydraulic lines shall be sufficiently sized to prevent cavitation or starvation and undue temperature variation or turbulence. Hydraulic lines shall have a sufficient pressure rating to withstand 2 times the design operating pressure of the hydraulic system.

H. Material of the hydraulic lines from the gate house to the gate tower and inside the gate tower shall be seamless stainless steel conforming to ASTM A 312, Grade TP316, and shall be joined with socket weld connections.

Material of the hydraulic lines from the gate tower to the guard gate shall be rubber hose with braided stainless steel reinforcement and shall comply with SAE J517. In addition a length of rubber hose (minimum 18 inches long) with braided stainless steel reinforcement complying with SAE J517 shall be used to connect the stainless steel hydraulic lines to the control gate actuator and low-flow gate actuator. See the Drawings for location and lengths of hydraulic lines.

I. Hydraulic lines, gate operators and all integral electrical position sensing components shall be designed for outdoor and underwater installation, suitable for extreme temperatures (-30 to 120 degrees Fahrenheit) at the site.

J. Hydraulic oil shall be non-petroleum-based biodegradable or “food grade” hydraulic fluid, compatible with drinking water standards for raw water, and suitable for extreme temperatures (-30 to 120 degrees Fahrenheit) at the site.

2.9 HYDRAULIC POWER UNIT AND BACKUP GENERATOR

A. Hydraulic Power Unit (HPU) shall be an oil-filled hydraulic actuator system capable of operating all three sluice gates and suitable for operation at an altitude of 8050 feet and a temperature range of -30 to 120 degrees Fahrenheit at the site. The HPU shall be designed for water control gate loading conditions (including, but not limited to, gate operating and design loads) provided by water control gate manufacturer, and conform to AWWA C540.

B. HPU shall provide safe, reliable and smooth operation, without binding, vibration, noise or heat, and be capable of maintaining the sluice gates in any position from fully open to fully closed, without drift.

C. HPU shall be a nominal 2,000 psi hydraulic fluid system of sufficient size and capacity to operate the gate hydraulic cylinders for the specified range of operating requirements and at a extend and retract speed of 12 inches per minute.

D. HPU shall be a complete skid-mounted unit, fully assembled and tested by the manufacturer. The skid shall include at a minimum:

1. Control panel

2. Two hydraulic pumps (1 operational, 1 stand-by)

3. Two electric motors (1 operational, 1 stand-by)

4. Oil reservoir

5. Oil filters

6. Accumulator tank

7. Solenoid operated directional control valves

8. Pressure relief valve

9. Counterbalance valve

10. Pressure switch

11. Pressure gauge

12. Oil level, high oil temperature, and low oil pressure gauges with dry contact outputs

13. Inter-connecting piping

14. Back-up hydraulic hand pump

E. HPU shall be designed to operate on 240 volt, 60 hertz, single phase alternating current. The HPU shall be capable of operating on power provided by the local utility company and a backup power generator in the event of a power loss.

F. Two oil pumps shall be provided. One oil pump will be the main and the second oil pump will be the backup. The oil pumps shall be positive displacement type, meeting the pressure and flow condition requirements for opening and closing the gates, and suitable for operation with the hydraulic oil specified.

G. Two electric motors shall be provided, one for each hydraulic pump. The electric motors shall be totally enclosed, and fan cooled, with cast iron frames, providing the necessary power to operate the hydraulic pumps at the maximum pressure required without exceeding the nameplate rating.

The motors shall be operated on 240 volt, 60 hertz, single phase alternating current, at an altitude of 8,050 feet, and a temperature range of -30 to120 degrees Fahrenheit.

H. A gasoline powered, 240 volt, 60 hertz, single phase alternating current backup generator, capable of starting and operating the HPU pumps, valves and gate control panel equipment under full load shall be provided.

Efficiency and fuel capacity of the generator shall allow 10 hours of run time on a full tank of gasoline.

2.10 CONTROL PANEL

A. A control panel capable of independently controlling each of the three sluice gate operators shall be provided with the HPU system. The control panel shall be factory furnished in a NEMA 12 rated electrical enclosure and come mounted on the HPU skid and be fully wired and tested by the manufacturer.

B. The control panel will allow an operator to fully open, fully close and modulate each of the three sluice gates. The control panel shall be provided with a 3-position control switch with OPEN, OFF, CLOSE positions for each gate. Provide a 4-digit digital panel meter for position indication of the low flow and control gates. Provide RED and GREEN LED pilot lamps for indicating the fully open and fully closed positions for each gate, Provide RED, YELLOW and GREEN LED pilot lamps for alarm and status indications of HPU oil temperature, pressure, level and filter status. Gate position shall be shown on the digital panel meter in inches with one tenth of an inch resolution.

2.11 PAINTING AND COATING

A. Painting and coating for all components shall be as recommended by the manufacturer. All painting and coating shall be shop applied with any areas damaged during shipment or handling to be repaired at the direction of the Engineer. Paint colors shall be the sluice gate manufacturer’s standard colors unless otherwise directed by the Engineer.

2.12 SHOP GATE TESTING

A. The gate manufacturer shall schedule an inspection by the Engineer at the factory prior to releasing the gates for delivery. During the inspection, the manufacturer shall arrange to demonstrate the operation of each sluice gate through a full cycle with the hydraulic operator and HPU provided with the gates without sticking or binding. Any adjustments or corrections shall be made until the sluice gates operate properly.

B. The HPU shall be test-operated in the shop to ensure that it delivers the required quantity of oil at the specified pressure. The relief valve shall be adjusted to maintain the specified pressure during testing. The HPU shall be operated during the testing to demonstrate that all the hydraulic and electrical components function properly. Discharge from the hydraulic pumps shall be measured for 15 minutes, and any observed leaks shall be repaired, and the HPU shall be retested.

C. The shop gate testing shall be witnessed by the Engineer and the gate manufacturer shall provide a minimum of 21 calendar days’ notice of when the shop testing will be scheduled. If the complete gate system is not ready to be shop tested on the day scheduled, the gate manufacturer shall reimburse the Owner for the Engineer’s travel, time and expenses at the Engineer’s billing rate.

PART 3 - EXECUTION

3.1 INSTALLATION OF GATES - GENERAL

A. The sluice gates shall be installed and adjusted in a competent manner and in accordance with the gate manufacturer’s recommendations.

B. The gate manufacturer shall furnish necessary drawings and detailed installation, operation, and maintenance instructions for all components.

C. The Contractor shall provide the manufacturer’s recommended lubricants.

D. The sluice gates shall be inspected and certified by a manufacturer’s representative for proper installation and functioning.

E. Installation of the gates shall follow the overall construction sequence for the outlet works. Refer to Section 01100: Construction Sequence.

3.2 INSTALLATION OF GUARD GATE UNDERWATER

A. Provide temporary support of the guard gate while the gate is attached to the ring flange and before guard gate braces are installed.

B. Match bolt holes in the gate frame to the bolt holes in the ring flange. The orientation of the bolt holes in the ring flange shall match the orientation of the bolt holes in the gate frame while the ring flange is welded to the steel conduit liner. Coordination of the Contractor with the gate manufacturer is required.

C. Install gate frame, gate leaf, and hydraulic cylinder as recommended by the gate manufacturer.

D. Connect hydraulic lines from the hydraulic cylinder and install the lines inside the 18-inch-diamter utility pipe on the upstream slope of the dam.

E. Install braces to the gate frame, as shown on the Drawings.

F. Connect hydraulic lines to the hydraulic power unit.

G. Fill the lines and cylinder with oil and bleed air from hydraulic cylinder and hydraulic lines as instructed by the manufacturer.

3.3 INSTALLATION OF CONTROL GATE

A. Place gate thimble in the gate chamber at the location shown on the Drawings.

B. Place structural concrete around the gate thimble in accordance with Section 03300: Cast-in-Place Concrete. Allow the concrete to cure for a minimum of seven (7) days before mounting the control gate.

C. Install gate frame, gate leaf, and hydraulic cylinder as recommended by the gate manufacturer.

D. Connect hydraulic lines from the hydraulic cylinder and install the lines inside the gate tower.

F. Connect hydraulic lines to the hydraulic power unit.

G. Fill the lines and cylinder with oil and bleed air from hydraulic cylinder and hydraulic lines as instructed by the manufacturer.

3.4 INSTALLATION OF LOW-FLOW GATE

A. The low-flow gate shall be connected to the existing flange as shown on the Drawings.

B. Install gate frame, gate leaf, and hydraulic cylinder as recommended by the gate manufacturer.

C. Connect hydraulic lines from the hydraulic cylinder and install the lines inside the gate tower.

D. Connect hydraulic lines to the hydraulic power unit.

E. Fill the lines and cylinder with oil and bleed air from hydraulic cylinder and hydraulic lines as instructed by the manufacturer.

3.5 FIELD TESTING

A. A manufacturer’s representative of the gate manufacturer shall be present for the field-testing of the sluice gates installed. The manufacturer’s representative shall provide written certification that the gates were installed in accordance with the manufacturer’s instructions.

B. Prior to acceptance by the Engineer, the Contractor shall operate each sluice gate through five (5) complete cycles using the hydraulic operators without sticking or binding. Any adjustments or corrections shall be made until the sluice gates operate properly.

C. Field gate testing shall be witnessed by the Engineer.

- END OF SECTION 11285 -