Specifications Rev Attachment 1.pdf

Specifications New Miter Gate Operating and Valve Operating Hydraulic Cylinders

Braddock L/D

PART 1 GENERAL

1.1 Unit Price Payment Items

1.1.1 General

1.1.2 Unit Price Items

1.1.2.1 Gate Operating Machinery Cylinder

1.1.2.2 Valve Operating Machinery Cylinder

1.2 REFERENCES

1.3 SITE VISITS

1.4 SYSTEM DESCRIPTION

1.4.1 Coordination Meeting and Point of Contact

1.5 SUBMITTALS

1.5.1 Summary

1.5.2 Definitions

1.5.2.1 Approving Authority

1.5.2.2 Submittal Description

1.5.3 Preparation

1.5.3.1 Format of SD-02 Shop Drawings

1.5.4 Quantity of Submittal

1.5.4.1 Number of Copies of SD-10 Operations and Maintenance Data

1.6 SCHEMATIC AND DRAWINGS

1.6.1 Shop Drawings

1.6.2 Fabrication Drawings

1.6.3 Shop Assembly Drawings

1.6.4 Weld Procedures and Qualifications

1.7 DELIVERY, STORAGE, AND HANDLING

1.7.1 Packaging

1.7.2 Shipping, Preservation, and Storage

1.8 WARRANTY

1.9 OPERATION AND MAINTENANCE

1.10 DELIVERY

1.11 ACCESS AND GENERAL PROTECTION/SECURITY PROCEDURES

1.12 FABRICATOR QUALIFICATIONS

1.13 PROJECT SCHEDULE

PART 2 PRODUCTS

2.1 MATERIALS AND MECHANICAL EQUIPMENT

2.1.1 General

2.1.2 Hydraulic Cylinders

2.1.2.1 Piston Rods

2.1.2.2 Pistons

2.1.2.3 Front Cylinder Head

2.1.2.4 Rear Cylinder Head

2.1.2.5 Packing Seat and Stuffing Gland

2.1.2.6 Rod Wiper

2.1.3 Bolts, Nuts, and Washers

2.1.3.1 Carbon Steel Bolts and Nuts

2.1.3.2 Stainless Steel Bolts and Nuts

2.1.3.3 Flat Washers

2.1.4 Seals, O-Rings, and Bearing Materials

2.1.4.1 Piston Wear Rings

2.1.4.2 O-Ring Seals

2.1.4.3 Piston Seals

2.1.4.4 Piston Rod Seals

2.1.5 Cylinder Supports

2.1.6 Cylinder Port Connections

2.1.7 Hydraulic Fluid

2.2 SHOP ASSEMBLY AND TESTING

2.2.1 Cylinder Tests

PART 3 EXECUTION

3.1 EXAMINATION

3.2 INSTALLATION

3.2.1 Cleaning and Flushing the System

3.2.2 Filling and Bleeding the System

3.3 PAINTING

-- End of Section Table of Contents –

PART 1 GENERAL

1.1 UNIT PRICE PAYMENT ITEMS

1.1.1 General

The unit price and payment made for each item listed shall constitute full compensation for furnishing all plant, labor, materials, equipment, tests and reports, and for performing all work required for each of the unit price items and delivering the items as specified. The two (2) new miter gate operating hydraulic cylinder and one (1) new valve operating hydraulic cylinder must be delivered to PEWARS within 180 calendar days after official notice of Contract Award.

1.1.2 Unit Price Items

1.1.2.1 Gate Operating Machinery Cylinder

Unit price payment items include:

CLIN 0001 MITER GATE OPERATING HYDRAULIC CYLINDER

a. The unit price and payment made for each item listed shall constitute full compensation for furnishing all plant, labor, materials, equipment, tests and reports, and for performing all work required for each of the unit price items.

b. Measurement for fabrication, painting and delivery of the new hydraulic cylinder shall be based on the actual number of cylinders tested and delivered by the Contractor, as approved by the Contracting Officer.

c. Unit of measure: Each (EA).

1.1.2.2 Valve Operating Machinery Cylinder

CLIN 0002 VALVE OPERATING HYDRAULIC CYLINDER

a. The unit price and payment made for each item listed shall constitute full compensation for furnishing all plant, labor, materials, equipment, tests and reports, and for performing all work required for each of the unit price items.

b. Measurement for fabrication, painting and delivery of the new hydraulic cylinder shall be based on the actual number of cylinders tested and delivered by the Contractor, as approved by the Contracting Officer.

c. Unit of measure: Each (EA).

1.2 REFERENCES

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.

THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B31.1 (2018) Power Piping

ASME BPVC SEC VIII (2019) Rules for Construction of Pressure Vessels

ASME BPVC SEC IX (2019) Welding, Brazing, and Fusing Qualifications

ASTM INTERNATIONAL (ASTM)

ASTM A36 (2018) Standard Specification for Carbon Structural Steel

ASTM A106/A106M (2019a) Standard Specification for Seamless Carbon Steel Pipe for High-Temperature Service

ASTM A108 (2018) Standard Specification for Steel Bar, Carbon and Alloy, Cold-Finished

ASTM A181/A181M (2014) Standard Specification for Carbon Steel Forgings, for General-Purpose Piping

ASTM A193/A193M (2019) Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High- Temperature Service and Other Special Purpose Applications

ASTM A194/A194M (2020) Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High-Pressure or High-Temperature Service, or Both

ASTM A216/216M (2018) Standard Specification for Steel Castings, Carbon, Suitable for Fusion Welding, for High-Temperature Service

ASTM A266/A266M (2018) Standard Specification for Carbon Steel Forgings for Pressure Vessel Components

ASTM A354 (2017) Standard Specification for Quenched and Tempered Alloy Steel Bolts, Studs, and Other Externally Threaded Fasteners

ASTM A516/A516M (2017) Standard Specification for Pressure Vessel Plates, Carbon Steel, for Moderate and Lower-Temperature Service

ASTM A536 (1984; R 2019) Standard Specification for Ductile Iron Castings

ASTM B505/B505M (2018) Standard Specification for Copper-Base Alloy Continuous Castings

ASTM B584 (2014) Standard Specification for Copper Alloy Sand Castings for General Applications

ASTM D624 (2000; R 2020) Standard Test Method for Tear Strength of Conventional Vulcanized Rubber and Thermoplastic Elastomers

ASTM D3951 (2018) Commercial Packaging

ASTM F3125/F3125M (2019) Standard Specification for High Strength Structural Bolts and Assemblies, Steel and Alloy Steel, Heat Treated, Inch Dimensions 120 ksi and 150 ksi Minimum Tensile Strength, and Metric Dimensions 830 MPa and 1040 MPa Minimum Tensile Strength

ASTM F844 (2007a, R 2013) Washers, Steel, Plain (Flat), Unhardened for General Use

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2018) Structural Welding Code - Steel

1.3 SITE VISIT

The awarded contractor must verify exact measurements with a site visit prior to submission of shop drawings and beginning any fabrication. To arrange a site visit contact the following personnel:

Braddock Lock and Dam Lockmaster – Kerry Skelley, (412)-271-0754 11th Street Braddock, PA 15104

Site visits will be arranged between the hours of 7:30 AM and 2:30 PM, Monday through Friday, excluding Federal holidays. A site visit must occur no later than 30 days after official notice of Contract Award.

A list of Federal holidays, can be found at https://www.opm.gov/policy-data-oversight/pay-leave/pay-administration/fact-sheets/holidays-work-schedules-and-pay.

1.4 SYSTEM DESCRIPTION

The work covered by this section of the specifications consists of detailed requirements for the fabrication, shop assembly, testing, and delivery of two (2) new hydraulic miter gate operating cylinder and one (1) new hydraulic valve operating cylinder. These items shall be furnish as new and manufactured per the specifications and drawings.

Exact dimensions and details of the existing hydraulic cylinders as installed in the field may vary from what is shown on the reference drawings (Attachment 2). Therefore, a site visit is required to verify layout details and measurements of each hydraulic cylinder prior to submitting shop drawings and beginning any fabrication.

1.4.1 Coordination Meeting and Point of Contact

Prior to the commencement of any work, the contractor shall participate in a pre-work teleconference with the Contracting Officer Representative (COR), Denise Polizzano. The technical aspects of the work, submittals, and schedule will be discussed during this initial meeting.

COR – Denise Polizzano, 412-395-7680 E-mail – Denise.M.Polizzano@usace.army.mil

COR Office Address:

Upper Ohio Resident Office 3510 Grand Avenue Pittsburgh, PA 15225 Office: (412) 395-7680

1.5 SUBMITTALS

Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for Contractor Quality Control approval. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government.

SD-01 Preconstruction Submittals;

Inspector Qualifications G, RO Project Schedule G, RO Qualifications of Welders and Welding Operators G, RO Thermal Stress Relief G, DO

SD-02 Shop Drawings;

Schematic and Drawings G, DO Welding Procedure Specifications G, DO https://www.opm.gov/policy-data-oversight/pay-leave/pay-administration/fact-sheets/holidays-work-schedules-and-pay https://www.opm.gov/policy-data-oversight/pay-leave/pay-administration/fact-sheets/holidays-work-schedules-and-pay mailto:Denise.M.Polizzano@usace.army.mil

SD-03 Product Data;

Materials and Mechanical Equipment G, DO Shop Assembly and Testing G, DO

SD-06 Test Reports;

Shop Tests G, DO Welds G, DO Materials G, DO

SD-10 Operation and Maintenance Data;

Operation and Maintenance G, DO

SD-11 Closeout Submittals;

Red-line Revision of Shop Drawings G, DO

1.5.1 SUMMARY

The Contracting Officer may request submittals in addition to those specified when deemed necessary to adequately describe the work covered in the respective sections.

Units of weights and measures used on all submittals are to be the same as those used in the reference drawings.

Each submittal shall be complete and in sufficient detail to allow ready determination of compliance with contract requirements.

Submittals requiring Government approval shall be scheduled and made prior to the acquisition of the material or equipment covered thereby.

Except as specified otherwise, allow review period, beginning with receipt by approving authority, that includes at least 20 days.

1.5.2 DEFINITIONS

1.5.2.1 Approving Authority

Office or designated person authorized to approve submittal.

1.5.2.2 Submittal Descriptions (SD)

Submittals requirements are specified in the technical sections.

Submittals are identified by Submittal Description (SD) numbers and titles as follows:

SD-01 Preconstruction Submittals

Submittals which are required prior to start of construction (work).

SD-02 Shop Drawings

Drawings, diagrams and schedules specifically prepared to illustrate some portion of the work.

Drawings prepared by or for the Contractor to show how multiple systems and interdisciplinary work will be coordinated.

SD-03 Product Data

Catalog cuts, illustrations, schedules, diagrams, performance charts, instructions and brochures illustrating size, physical appearance and other characteristics of materials, systems or equipment for some portion of the work.

Samples of warranty language when the contract requires extended product warranties.

SD-06 Test Reports

Report signed by authorized official of testing laboratory that a material, product or system identical to the material, product or system to be provided has been tested in accord with specified requirements. (Testing must have been within three years of date of contract award for the project.)

Report which includes findings of a test required to be performed by the Contractor on an actual portion of the work or prototype prepared for the project before shipment to job site.

Report which includes finding of a test made at the job site or on sample taken from the job site, on portion of work during or after installation.

Daily logs and checklists.

Final acceptance test and operational test procedure.

SD-10 Operation and Maintenance Data

Data that is furnished by the manufacturer, or the system provider, to the equipment operating and maintenance personnel, including manufacturer's help and product line documentation necessary to maintain and install equipment. This data is needed by operating and maintenance personnel for the safe and efficient operation, maintenance and repair of the item.

This data is intended to be incorporated in an operations and maintenance manual or control system.

SD-11 Closeout Submittals

Documentation to record compliance with technical or administrative requirements or to establish an administrative mechanism.

Special requirements necessary to properly close out a construction contract. For example, Record Drawings and as-built drawings.

1.5.3 PREPARATION

Provide all submittals in electronic format with the exception of the operations and maintenance manuals. Electronic files must be of sufficient quality that all information is legible. Use PDF as the electronic format unless otherwise specified or directed by the Contracting Officer or designated representative.

1.5.3.1 Format for SD-02 Shop Drawings

Shop drawings are not to be less than 11 by 17 inches nor more than 30 by 42 inches, except for full size patterns or templates. Prepare drawings to accurate size, with scale indicated, unless other form is required. Drawings are to be suitable for reproduction and be of a quality to produce clear, distinct lines and letters with dark lines on a white background.

Include on each drawing the drawing title, number, date, and revision numbers and dates.

Number the drawings in a logical sequence. Each drawing is to bear the number of the submittal in a uniform location adjacent to the title block. Place the Government contract number in the margin, immediately below the title block, for each drawing.

Dimension drawings, except diagrams and schematic drawings; prepare drawings demonstrating interface with other trades to scale. Use the same unit of measure for shop drawings as indicated on the contract drawings. Identify materials and products for work shown.

Include the nameplate data, size and capacity on drawings. Also include applicable federal, military, industry and technical society publication references.

1.5.4 QUANTITY OF SUBMITTALS

1.5.4.1 Number of Copies of SD-10 Operation and Maintenance Data

Submit three hard copies of O&M Data to the Contracting Officer for review and approval.

1.6 SCHEMATIC AND DRAWINGS

1.6.1 Shop Drawings

Detailed shop drawings shall include fabrication and shop assembly drawings. Any component part of fabricated items omitted shall be detailed on the shop drawings. If departures from the contract drawings are deemed necessary by the Contractor, submit details of such departures, including changes in related portions of the project and reasons thereof, with the shop drawings. It is not acceptable to reproduce contract drawings for submission as shop or fabrication drawings.

1.6.2 Fabrication Drawings

Provide fabrication drawings for all mechanical and structural parts or components, except those which are of standard manufacture. The drawings shall show complete details of materials, tolerances, machined surface finishes, connections, and proposed welding sequences which differentiate shop welds and field welds.

1.6.3 Shop Assembly Drawings

Provide shop assembly drawings with details for connecting the adjoining fabricated components in the shop to ensure satisfactory field installation.

1.6.4 Weld Procedures and Qualifications

Provide weld procedures for each weld. Each weld must be individually identified and as referenced on the shop and fabrication drawings. Copies of certificates showing evidence of qualifications or certifications for welders, welding operators and weld inspectors must be submitted prior to fabrication commencing. Design welded connections in accordance with AWS D1.1/D1.1M except that provisions for repeated stress is not required. Weld hydraulic cylinders in accordance with ASME BPVC SEC VIII D1. Qualify procedures and welders 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 within 48 hours in advance of tests and perform the tests at the work site if practicable. Apply the welder's or welding operator's assigned symbol near each weld made as a permanent record. Submit a copy of qualified procedures and a list of names and identification symbols of qualified welders and welding operators. Provide proposed stress relief heat treatment for approval.

1.7 DELIVERY, STORAGE, AND HANDLING

1.7.1 Packaging

The hydraulic cylinders shall not be prepared for shipment until they have been inspected and accepted for shipment at origin by the Government Point of Contact, unless inspection has been waived in writing. Each hydraulic cylinder shall be shipped completely assembled.

Provide the subassemblies with adequate protective pads, supports, and blocking and securely restrained to prevent distortion or damage to the painted surfaces in transit. 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 without cost to the Government. Standard commercial packaging in accordance with ASTM D3951 will be acceptable except where a different method or standard of packaging is specified.

1.7.2 Shipping, Preservation, and Storage

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 equipment. The hydraulic cylinders shall be filled with the specified hydraulic fluid and the piping connections sealed. The shipping provisions shall be such that the cylinders may be rotated in increments of 90 degrees during storage. Should the cylinders be stored by the Contractor during fabrication or shipping in the horizontal position for more than 30 days, they shall be rotated every 30 days as follows: first 90 degrees, then 180 degrees, then 90 degrees, and then 180 degrees. Provisions shall be made to prevent damage to the cylinder and piston rod resulting from the rod flexing up and down in the cylinder during transport. Submit a proposal for controlling movement of the piston rod for approval. It is suggested to extend the rod a short distance, provide a bracket so that the rod cannot be retracted. Adequately protect machined surfaces from corrosion and physical damage. Protect equipment delivered and placed in storage from the weather, humidity, temperature variation, dirt and dust, or other contaminants.

1.8 WARRANTY

All equipment shall be guaranteed for a period of 2 years from the date of acceptance after delivery. Replacement parts shall be guaranteed for 2 years from date of replacement. Provide Warranty against defective materials, design, and workmanship. In cases where the equipment manufacturer's advertised minimum guarantee is in excess of 2 years, it shall remain in force for its full period. Upon receipt of notice from the Government of failure of any of the parts during the warranty period, new replacement parts shall be furnished and installed promptly at no additional cost to the Government.

1.9 OPERATION AND MAINTENANCE

Furnish 3 complete sets of instructions containing the manufacturer's operation and maintenance instructions for each piece of equipment to the Contracting Officer Representative. Each set shall be permanently bound and shall have a hard cover. Furnish one complete set prior to shop testing and the remaining sets shall be furnished before the contract is completed. The following identification shall be inscribed on the covers: "OPERATING AND MAINTENANCE INSTRUCTIONS," title of the project, location of the project, the name of the Contractor, and the contract number. A flysheet shall be placed before instructions covering each subject. The instruction sheets shall be approximately 8-1/2 by 11 inches, with large sheets of drawings folded in. The instructions shall include, but not be limited to, the following:

a. A cross-section drawing of the hydraulic cylinder with parts list.

b. Operating and maintenance instructions.

c. Manufacturer's bulletins, catalog cuts, and descriptive data.

Provide the Operation and Maintenance (O&M) Manual with all information which may be needed or useful for operation, maintenance, repair, dismantling or assembling, and for identification of parts for ordering replacements.

The manual will be subject to approval.

1.10 DELIVERY

The hydraulic cylinders shall be delivered to:

U.S. Army Corps of Engineers Pittsburgh Engineer Warehouse and Repair Shop (PEWARS) 3500 Grand Avenue

Pittsburgh, Pennsylvania 15225-1510 Telephone No. 412-395-7615 Attn: Jason Shackleford

Shipments are received between 8:00 a.m. and 3:00 p.m., Monday through Thursday, Federal Holidays excluded. A Government crane will be available at PEWARS to unload the cylinders. The Contractor shall notify the Government at least thirty (30) calendar days prior to the date of delivery.

The two (2) new miter gate operating hydraulic cylinder and one (1) new valve operating hydraulic cylinder must be delivered to PEWARS within 180 calendar days after official notice of Contract Award.

1.11 ACCESS AND GENERAL PROTECTION/SECURITY POLICY PROCEDURES

The contractor and all associated subcontractors' employees shall comply with applicable installation, facility, and area commander installation and facility access and local security policies and procedures (provided by the Government Representative). The contractor shall also provide all information required for background checks to meet installation access requirements to be accomplished by the installation the USACE Security Office. The contractor workforce must comply with all personal identity verification requirements as directed by DOD, HQDA, and/or local policy. In addition to the changes otherwise authorized by the changes clause of this contract, should the Force Protection Condition (FPCON) at any individual facility or installation change, the Government may require changes in contractor security matters or processes. The contractor must submit the full name, Social Security Number/or a valid driver’s license number with state of issue, Date of Birth, and Place of Birth/Citizenship for all associated contractor or subcontractor employees to the USACE Security Office, Joseph M. Bali, 412-395-7162, joseph.m.bali@usace.army.mil. Attachment 6, Security Background Check Form, is to be completed in its entirety and submitted to the USACE Security Office. To protect employee PII, the submission of the completed form through a secure fax is preferred; however, a secured email is acceptable. The District retains the right to deny any contractor and subcontractor employee from working on one of its contracts based on final background investigation results.

Contractors who do not require Common Access Card (CAC), but require access to a DOD facility or installation

Contractor and all associated sub-contractors employees shall comply with adjudication standards and procedures using the National Crime Information Center Interstate Identification Index (NCIC-III) and Terrorist Screening Database (TSDB) (Army Directive 2014-05 / AR 190-13), applicable installation, facility and area commander installation/facility access and local security policies and procedures (provided by government representative, as NCIC and TSDB are available), or, at OCONUS locations, in accordance with status of forces agreements and other theater regulations.

Pre-screen candidates using E-Verify Program

The Contractor must pre‐screen Candidates using the E‐verify Program (https://www.e-verify.gov/) website to meet the established employment eligibility requirements. The Vendor must ensure that the Candidate has two valid forms of Government issued identification prior to ensure the correct information is entered into the E‐verify system.

An initial list of verified/eligible Candidates must be provided to the Contracting Officer or their designated representative no later than three (3) business days after the initial contract award.

1.12 FABRICATOR QUALIFICATIONS

The hydraulic cylinders must be fabricated by a firm having at least 5 years’ experience in fabrication of industrial hydraulic cylinders of similar size and function. The contractor shall submit with their quote experience and past projects to justify the years of experience. All work shall be performed in a skillful and workmanlike manner in accordance with the best modern shop practice for the manufacture of finished products of a nature similar to those covered by these specifications, and shall be performed by mechanics especially skilled for each kind of work and under competent supervision and direction. The fabricator shall install all parts used to fabricate the hydraulic cylinder system according to the recommendations of the manufacturer and/or supplier of the parts used in that mailto:joseph.m.bali@usace.army.mil https://www.e-verify.gov/ system.

1.13 PROJECT SCHEDULE

Provide a schedule defining the following information and their respective duration times: Notice to Proceed (start date), submittals, ordering materials, fabrication and assembly, shop testing, delivery, project completion and any other activities that may help monitor contract progress. Allow time for Government review time as mentioned above. A description of the scheduled activities shall be submitted as part to the package. The project schedule shall be forward planning as well as a project monitoring tool.

Provide a Schedule Status Report on at least a monthly basis. If, in the opinion of the Contracting Officer, the Contractor falls behind the approved schedule, take steps necessary to improve its progress including those that may be required by the Contracting Officer, without additional cost to the Government. In this circumstance, the Contracting Officer may require the Contractor to increase the number of shifts, overtime operations, days of work, and/or the amount of construction plant, and to submit for approval any supplementary schedule or schedules as the Contracting Officer deems necessary to demonstrate how the approved rate of progress will be regained.

Failure of the Contractor to comply with the requirements of the Contracting Officer shall be grounds for a determination, by the Contracting Officer, that the Contractor is not prosecuting the work with sufficient diligence to ensure completion within the time specified in the contract. Upon making this determination, the Contracting Officer may terminate the Contractor's right to proceed with the work, or any separable part of it, in accordance with the default terms of the contract.

PART 2 PRODUCTS

2.1 MATERIALS AND MECHANICAL EQUIPMENT

2.1.1 General

Provide materials and mechanical equipment that conform to the requirements indicated or specified, and if not specified, furnish materials and mechanical equipment of the best commercial grade quality suited to the intended use and as approved. The manufacturer's name, address, and catalog number shall be permanently displayed on a nameplate securely attached to each major item of equipment.

Submit data specifications and assembly drawings showing sizes, ratings, parts and material lists, overall dimensions, and mounting dimensions with the product data.

All cylinders must be rated at not less than 2,000 psi. Cylinders must be mill type, double acting, foot mounted and shall be exact replacements for the existing cylinders, requiring no modifications of existing components to install and operate the machinery correctly unless otherwise noted. Tie rod cylinders will NOT be acceptable.

Design all hydraulic cylinders to withstand a maximum operating pressure of 2,000 psi with a factor of safety of 5 based on the ultimate strength of the material or 2 based on the yield strength of the material. Apply a factor of safety of 3 to the compression load when designing the hydraulic cylinders to resist buckling. (Amendment 0002).

The following reference drawings (Attachment 2) are attached for the fabrication of the hydraulic cylinders:

037-L2-22/5.1 Gate Operating Machinery 110 Foot Lock Assembly

037-L2-22/6 Gate Operating Machinery 110 Foot Lock Cylinder and Details 037-L2-28/5.1 Butterfly Valve Operating Machinery 110 Foot Lock Assembly

037-L2-28/6 Butterfly Valve Operating Machinery 110 Foot Lock Cylinder and Details Assembly

All materials must adhere to those indicated on drawing 037-L2-22/6 for the Gate Operating Cylinders and drawing 037-L2-28/6 for the Valve Operating Cylinder UNLESS OTHERWISE STATED IN THIS

DOCUMENT.

2.1.2 Hydraulic Cylinders

The outside of the finished cylinders shall be turned concentric with the bore, and the interior shall be honed to the dimensions, tolerances, and finish shown in the reference drawings. Flanges shall be welded to the cylinder parallel with each other and perpendicular to the cylinder center line. Tolerances shall be as shown. After completion of all welding, the cylinder shall be stress relief heat treated. THE BORE OF EACH HYDRAULIC CYLINDER

MUST NOT BE CHROME PLATED.

All welds shall be radiographed including those on the end mounts. Radiographic inspection of welds shall be performed and evaluated in accordance with ASME BPVC SEC VIII D1 Part UW-51. Any welds that cannot be radiographic inspected must be ultrasonic inspected and evaluated in accordance with ASME BPVC SEC VIII D1 Mandatory Appendix 12. The assembled cylinder shall be of such straightness that the piston and rod move smoothly therein without any indication of binding or tight spots. Surface finishes shall be 10 to 15 microinch rms. The cylinder material must be steel conforming to the following:

Option A: Rolled steel plate in accordance with ASTM A516/A516M, Grade 70 or equivalent material as approved, and welded flanges in accordance with ASTM A181/A181M, Class 70 or equivalent material as approved.

Option B: Provide centrifugal cast steel shell in accordance with ASTM A216/A216M, Grade WWC or equivalent material as approved, and welded flanges in accordance with ASTM A181/A181M, Class 70 or equivalent material as approved, or cast from ASTM A216/A216M, Grade WWC steel or equivalent material as approved.

Option C: The shell and flanges a solid trepanned forging in accordance with ASTM A266/A266M, Class 1 or equivalent material as approved.

Option D: Seamless carbon steel pipe in accordance with ASTM A106/A106M, Grade C or equivalent materials as approved. (Amendment 0002).

For Hydraulic Gate Cylinder, reference drawing: 037-L2-22/6

For Hydraulic Valve Cylinder, reference drawing: 037-L2-28/6

2.1.2.1 Piston Rods

The piston rods shall be made of carbon steel with nickel and hard-chrome plating. The piston rod must be composed of one (1) solid piece. A piston rod composed of two or more pieces that are welded together is NOT permitted. Fabricate each piston rod from carbon steel conforming to ASTM A108, Type C 1045 or Type CR 4140 with a minimum tensile strength of 90,000 psi to 110,000 psi. (Amendment 0002). It shall be case hardened to 50-54 Rockwell C, polished to a 10 microinch RMS surface finish or better, and nickel and hard-chrome plated to 0.003 inch minimum thickness.

Plating must be in accordance with ASTM B177/B177M or ASTM B650. The final rod surface must have a roughness height of not more than 8 microinches Ra. Quantify the final rod surface roughness using the Rpk-Rk- Rvk in accordance with ISO 13565. Other parameters such as Ra, Rz or Rmax value can only be used indicative.

Roughness to be determined by Cylinder manufacturer and Seal manufacturer for the intended cylinder operating environment as specified. Submit certified test reports for both the rod material and performance requirements as specified.

All rod coatings to meet or exceed the minimum test criterion as stated in Table 1: (Nickel) Chromium Piston Rod Coating Requirements. (See Attachment 5).

For Hydraulic Gate Cylinder piston rod, reference drawing: 037-L2-22/6

For Hydraulic Valve Cylinder piston rod, reference drawing: 037-L2-28/6

2.1.2.2 Pistons

The piston shall be cast iron conforming to ASTM A536, Grade 80-55-06 or 10-50-05 70-50-05 (Amendment 0002).

Piston design shall have the same overall dimensions shown in the reference drawings. The piston shall be designed to accommodate piston bearings, seals and wear rings. The length dimensions of this section may be extended to a maximum of the overall length of the piston. The design shall protect the piston seals from blowout and over-squeezing and shall provide zero leakage. The dimensional information along with seal selection and geometry shall be submitted prior to fabrication for approval.

For Hydraulic Gate Cylinder piston, reference drawing: 037-L2-22/6

For Hydraulic Valve Cylinder piston, reference drawing: 037-L2-28/6

2.1.2.3 Front Cylinder Head

For Hydraulic Gate Cylinder front cylinder head, reference drawing: 037-L2-22/6

For Hydraulic Valve Cylinder front cylinder head, reference drawing: 037-L2-28/6

2.1.2.4 Rear Cylinder Head

For Hydraulic Gate Cylinder rear cylinder head, reference drawing: 037-L2-22/6

For Hydraulic Valve Cylinder rear cylinder head, reference drawing: 037-L2-28/6

2.1.2.5 Packing Seat and Stuffing Gland

The packing seat and stuffing gland shall be fabricated from bronze conforming to ASTM B505/B505M, Alloy No.

C95400 or C93200. If applicable, the ice scraper, attached to the gland, bronze-filled polytetrafluoroethylene in accordance with ASTM B584, Alloy No. C86300.

The packing seat and stuffing gland must allow removal and replacement of the rod wiper and piston rod packing without having to disconnect any components from the end of the piston rod. A split packing seat and split stuffing gland may or may not be required to accomplish this.

2.1.2.6 Rod Wiper

The rod wiper shall be scraper ring able to withstand the impact and the abrasion of materials adhering the piston rod. The material of the rod wiper must be a polyurethane recommended by the manufacturer and will be subject to USACE approval. The rod wiper must have a minimum tear resistance of 120 N/mm or 685.2 pounds per inch as measured in accordance with testing for Type C tear strength as per ASTM D624. Split and retain the rod wiper with split, bolted retainer to allow removal and replacement of the rod wiper without having to disconnect any components from the end of the piston rod.

2.1.3 Bolts, Nuts, and Washers

New bolts, nuts, plugs and fittings cross referenced in the drawings shall be provided as part of the contract.

2.1.3.1 Carbon Steel Bolts and Nuts

Carbon steel bolts and nuts shall conform to ASTM A354, Grade BC, with ASTM A194/A194M, Grade 2H nuts.

Structural bolted connections carrying primary loads shall be made with ASTM F3125 Grade A325 bolts.

2.1.3.2 Stainless Steel Bolts and Nuts

Stainless steel bolts and nuts shall conform to ASTM A193/A193M, Grade B8M Class 2 with ASTM A194/A194M, Grade 8M nuts.

2.1.3.3 Flat Washers

Flat washers shall conform to ASTM F844. Flat washers for structural bolted connections carrying primary loads shall conform to ASTM F436.

2.1.4 Seals, O-Rings, and Bearing Materials

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.

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.

Dynamic Seals

Dynamic seals may be lip, cup, V-ring, U-ring, flange, or squeeze type, unless otherwise specified or indicated.

2.1.4.1 Piston Wear Rings

The piston must have composite piston wear rings with a compressive and tensile strength of not less than 165 MPa or 24,000psi and an embedability capability to prevent scoring of the cylinder. The material of the piston wear rings is to be as recommended by the manufacturer and is subject to USACE approval.

2.1.4.2 O-Ring Seals

The O-ring seals shall be Buna N and designed for 2000 psi service.

2.1.4.3 Piston Seals

Piston seals shall be of the low leakage (“zero leakage”), low friction, dual acting type. They shall be nonadjustable, with high extrusion and wear resistance, and shall be compatible with the oil type specified for the system. The piston service pressure is 2000 psi. Leakage performance shall prevent the cylinder from drifting while stationary and prevent slip stick while in operation. The material of the piston seals is to be as recommended by the manufacturer and is subject to USACE approval.

2.1.4.4 Piston Rod Seals

The piston rod packing must be low leakage split chevron packing type designed for 2000 psi service. The piston rod packing must be split to allow removal and replacement of the packing without having to disconnect any components from the end of the piston rod.

2.1.5 Cylinder Supports

Cylinder supports shall be foot mounted and shall be fabricated as shown on the reference drawings. Coordinate supports with the anchor points as dictated by the site conditions, as they may slightly vary from the reference drawings. If anchor points vary, identify the cylinder and the location to be mounted.

2.1.6 Cylinder Port Connections

Pressure and return porting type and location shall match that of the existing cylinder to be replaced. An additional port shall be provided so the cylinder will have plugged ports provided on both sides of the cylinder's front and rear heads. This will allow the cylinders to be used in any location. A plugged 1/2-14 NPT top bleed/gage port and 1/2-14 NPT bottom drain port shall be provided at both ends of each cylinder.

2.1.7 Hydraulic Fluid

The hydraulic fluid to be used during shop testing and to fill the cylinders before shipment shall be Altra AW 32 Hydraulic Fluid manufactured by Allegheny Petroleum Products Co. Fresh hydraulic fluid shall be filtered through a 10 micron filter before it is added to the system. All oil shall be supplied by the Contractor.

2.2 SHOP ASSEMBLY AND TESTING

Each hydraulic cylinder shall be completely shop assembled and tested insofar as is possible using temporary piping to determine the correctness of fabrication and the matching of component parts to ensure acceptable operation after field erection. Submit test procedures. Shop tests shall be made in the presence of a representative of the Contracting Officer, unless otherwise authorized in writing. Upon satisfactory completion of the shop assembly and testing, preliminary acceptance will be made by the Contracting Officer. Final inspection and acceptance shall be made upon delivery to PEWARS.

2.2.1 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 2000 psi on each side of the piston (rod extended and retracted) for a minimum of 30 minutes with zero leakage from the rod end and piston seals. Any leakage past the seals shall be cause for rejection.

The cylinder rod and piston shall then be extended and observed for smooth, even travel. Any operational problems or source of leakage to the outside of the cylinder will be cause for rejection. Such conditions shall be corrected by the Contractor and a satisfactory retest conducted. All shop testing shall be performed in the presence of the Contracting Officer unless waived in writing. Certified test reports shall be furnished to the Contracting Officer. The temperature of the oil during the test shall be approximately 70 degrees F.

PART 3 EXECUTION

3.1 EXAMINATION

After visiting the site and becoming thoroughly familiar with all details of the work and working conditions, verify dimensions in the field, and then advise the Contracting Officer of any discrepancies prior to performing any work.

3.2 INSTALLATION

3.2.1 Cleaning and Flushing the System

During assembly, avoid the entrance of abrasives, dirt, metal chips, and other foreign materials into the hydraulic cylinder through open ends of piping, tubing, and ports of the components.

3.2.2 Filling and Bleeding the System

Oil used to fill the cylinder shall be filtered through a 10 micron filter. The hydraulic cylinders shall be filled in the horizontal position with the piping connections up to allow air to escape, and the piping shall be filled in a manner that excludes as much air as possible.

3.3 PAINTING

The Contractor shall be responsible for filling out a Daily Coating Inspection Report whenever painting or blasting activities are performed. A sample Paint Inspection Form has been provided in Attachment 4, Paint Coating Form.

All exposed exterior surfaces of the cylinder assembly except stainless steel, synthetic rubber, and plastic, shall be shop primed and coated as specified. Coat non-machined surfaces of the parts with two coats of Bar Rust 235, Haze Gray, Epoxy Coating, manufactured by Devoe High Performance Coatings; or an approved alternative epoxy coating system. Apply coating per manufacturer's recommendation. Chips, scratches, and other damage to shop- applied painted surfaces shall be repainted in conformance with this section.

-- End of Specifications –

3.3 PAINTING