2016_Gate_and_Valve_Cylinders_Tech_Spec.pdf

TABLE OF CONTENTS

Hydraulic Cylinders

PART 1 GENERAL

1.1 PAYMENT

1.2 REFERENCES

1.3 SUBMITTALS

1.4 QUALITY ASSURANCE

1.5 REQUIRED SITE VISIT FOR MEASUREMENTS

PART 2 PRODUCTS

2.1 GENERAL

2.2 HYDRAULIC CYLINDERS

2.2.1 Cylinder tubes

2.2.2 Cylinder Heads and Caps

2.2.3 Pistons

2.2.4 Piston rods

2.2.5 Hydraulic Hose and Piping

2.2.6 Hydraulic Fluid

2.2.7 Miscellaneous

2.3 MATERIALS

2.4 TESTS, INSPECTIONS, AND VERIFICATIONS

2.4.1 Shop Assembly and Testing

2.4.2 Material Tests

PART 3 EXECUTIONS

3.1 DELIVERY, STORAGE, AND HANDLING

3.2 CONTRACT COMPLETION DATE

3.3 LIQUIDATED DAMAGES

3.4 WARRANTY

-- End of Section Table of Contents –

HYDRAULIC CYLINDER SPECIFICATIONS

PART 1 GENERAL

The work covered by these specifications consists of detailed requirements for the fabrication, shop assembly, testing and delivery of four (4) hydraulic cylinders for the operation of the miter gates and one (1) hydraulic cylinder for the operation of the culvert valves at the Troy Lock and Dam, Troy, NY as specified and as shown.

1.1 PAYMENT

Payment will be made upon completion for costs associated with providing the fabrication, shop assembly, testing and delivery and acceptance of hydraulic cylinders for the operation of culvert valves and miter gates at the Troy Lock, 1 Bond Street, Troy NY 12180. Payments will be made according to the cylinders accepted and the bid price per unit. The unit prices for each hydraulic cylinder shall include full compensation for all plant, labor, materials, supplies, and delivery to the Troy Lock required to complete the work in accordance with the specifications.

1.2 REFERENCES

The publication listed below forms a part of this specification to the extent referenced. The publication is referred to within the text by the basic designation only. The drawings provided are included for reference only.

The drawings refer to the hydraulic cylinders produced circa 1952 and to the miter gate hydraulic cylinders produced circa 1997.

Construction Engineering Research Laboratory ERDC/CERL TR-02-7: Advanced Materials Selection Guide for Lock, Dam, and Hydroelectric Components

1952 Hydraulic Cylinder As-Built Drawings

1997 RMH Miter Gate Cylinder Shop Drawings

1.3 SUBMITTALS

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

SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Hydraulic Cylinders; G, AFO

Detail drawings to scale for the hydraulic cylinders, including fabricated sections, showing complete dimensions and details. Assembly drawings showing the complete hydraulic cylinder shall also be provided. The drawings shall show complete details of dimensions, materials, tolerances, machined surface finishes, connections, and proposed welding sequences which differentiate shop welds and field welds. To include “cut sheets” for all commercially available components. One (1) paper and one (1) electronic copy to be provided.

Hydraulic Cylinders, As Built Drawings; G, AFO

The “As-Built” drawings shall include a cross-section drawing of the hydraulic cylinder with parts list, and all information which may be needed or useful for operation, maintenance, repair, dismantling or assembling and for identification of parts for ordering replacements. One

(1) paper and one (1) electronic copy to be provided.

SD-03 Product Data

Seals; G, AFO

Rings; G, AFO

Bushings; G, AFO

Packing material; G, AFO

Hydraulic fluid; G, AFO

Coatings; G, AFO

SD-06 Test Reports

Assembled cylinder tests; G, AFO

Certified test reports showing that the cylinder materials and the assembled cylinders meet the specified requirements, for each cylinder, prior to delivery.

1.4 Quality Assurance

Material Certificates; G, AFO

Materials shall conform to the requirements indicated, and if not specified, then materials of the best commercial grade quality suited to the intended use and as approved shall be furnished. Submit certificates for each cylinder type.

1.5 REQUIRED SITE VISIT FOR MEASUREMENTS

Existing miter gate and culvert valve hydraulic cylinders are installed at the Troy Lock, 1 Bond Street, Troy NY 12180. Upon award of the contract, Contractor shall review the drawings provided for reference, and conduct a required visit to obtain measurements required for providing new hydraulic cylinders. The site visit may be scheduled by calling 518-273-0870, Monday through Friday, 0700 to 1530.

2. Hydraulic Cylinder Parts and Materials

2.1 Principal Design Parameters

The contract drawings indicate the general design, dimensions and features of the existing hydraulic cylinders. The new hydraulic cylinders shall be fabricated and assembled so as to universally meet the fit, form and function of the existing cylinders. The new hydraulic cylinders shall be able to withstand the maximum operating pressure in the system (2000 psi) with a factor of safety of five (5) based on the ultimate strength of the material or two (2) based on the yield strength of the material. A factor of safety of three (3) shall be applied to the compression load when designing the hydraulic cylinder to resist buckling. Prospective bidders are encouraged to visit the Troy Lock and Dam site, located at 1 Bond Street, Troy, NY 12180 to inspect the existing hydraulic cylinders and record any measurements needed, as the drawings provided are for reference only and the hydraulic cylinders to be provided are similar to those in operation at the lock. The successful bidder is required upon award to conduct a site visit and verify the conditions and hydraulic cylinder dimensions and materials as currently constructed.

2.2 Materials

Materials shall conform to the requirements indicated, and if not specified, then materials of the best commercial grade quality suited to the intended use, and as approved, shall be furnished. Where items are referred to hereinafter 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 a reputable manufacturer regularly engaged in the commercial production for at least two (2) years prior to this solicitation of the type and quality of material or equipment referred to, subject to approval by the Contracting Officer, will not be excluded on the basis of minor differences, provided essential requirements of the specifications relative to materials, capacity, and performance are met.

Furnish performance capacities and other pertinent information concerning the manufacturer's "equal to" standard products intended for incorporation in the work. "Equal to" standard products installed or used without such approval are at the risk of subsequent rejection.

2.3 Hydraulic Cylinders

The hydraulic cylinders shall be of the type designed and manufactured to meet the criteria stated in paragraph Principal Design Parameters. The bore, stroke and mounting style of the cylinders shall be as those in operation at the Troy Lock. The manufacturer shall produce evidence that the cylinders were hydrostatically tested to 200 percent of the severest service rating (maximum operating pressure = 2000 psi) and that dynamic seals are suitable for both frequent and infrequent operation and are capable of not less than 500,000 cycles of operation in systems properly maintained. 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 as indicated. The hydraulic cylinder shall be provided with cushions as per the existing. The piping ports shall be compatible with the existing hydraulic lines. All exposed exterior surfaces except stainless steel, chrome, synthetic rubber and plastic shall be shop primed and coated with a paint system suitable for the conditions that the hydraulic cylinder will be operating in. Color shall be a gray darker than that on the existing cylinders.

2.3.1 Cylinder Tubes

The cylinder tubes shall be machined from one of the following materials: ASTM A 519, Grade 1018, heavy wall seamless steel tubing; a material selected from ERDC/CERL TR-02-07, Table 3;

or a material submitted and approved, equivalent to that shown in the table or on the drawings. The bore shall be honed to a surface finish compatible with the seals being used so as to result in zero leakage past the seals.

2.3.2 Cylinder Heads and Caps

The cylinder head and cap shall be made from one of the following materials: ASTM A 576, Grade 1018, steel bar stock; ASTM 516/A 516M, Grade 60 plate, a material selected from ERDC/CERL TR-02-7 Table 3 or a material submitted and approved equivalent to that shown in the table or on the drawings. The cylinder head shall be machine finished on all surfaces. Equip the cylinder head with a rod seal and external dirt wiper and a rod bushing piloted into the head to ensure concentricity. Rod bushings must be removable without the use of special tools and without removing the tie rods or cylinder head. Attach the cylinder tube to the head and cap by tie rods having a minimum yield strength of 690 MPa 100,000 psi. Removable attachments must have the cylinder tube end seals arranged to seal with pressure and be designed to prevent shearing and to provide axial metal backup.

2.3.3 Pistons

The piston shall be precision fitted to the body bore. The piston must be cast iron conforming to ASTM A536, Grade 80-55-06 or 10-50-05, or a material selected from ERDC/CERL TR-02-7 table 3. The piston must be designed and equipped with zero leakage self-regulation O-ring loaded U-cup-type seals that automatically compensate for wear. The design must protect the piston rings from blow-out and oversqueezing.

2.3.4 Piston Rods

The material shall be selected from ERDC/CERL TR-02-7, Table 3 or a material submitted and approved equivalent to that shown in the table. The rod must be case hardened to 50-54 Rockwell C, polished to a 0.25 micrometer 10 microinch RMS surface finish or better, and nickel and hard-chrome plated to 75 micrometer 0.003 inch minimum thickness. The final rod surface after chrome plating shall be compatible with the seals being used so as to result in zero leakage past the seals.

2.3.5 Piston Wear Rings

Provide glass-reinforced nylon piston wear rings with a compressive and tensile strength of not less than 165 MPa 24,000 psi and an embedability capability to prevent scoring of the cylinder.

2.3.6 O-Ring Seals

Use O-ring seals of Viton and designed for appropriate service.

2.3.7 Rod Wiper/Scraper

Provide a high-strength polyurethane scraper ring which will withstand the impact and the abrasion of materials adhering to the piston rod. Split and retain the scrapers with split, bolted retainer to facilitate replacement without removal of the rod end clevis.

2.3.8 Piston Rod Seals

Provide low leakage V-ring, nonadjustable gland type piston rod seals, designed for indicated service.

2.3.9 Rod Seal Gland and Locking Device Flange

Fabricate the rod seal gland and locking device flange from bronze conforming to ASTM B505/B505M, Alloy No. C95400 or C93200. The ice scraper, attached to the gland, must conform to ASTM B584, Alloy No. C86300.

2.4 Hydraulic Hose and Piping

Hydraulic Hose and Piping shall be rated for the working pressure and severe service environment of the hydraulic cylinder.

2.5 Hydraulic Fluid

The hydraulic fluid to be used to fill the cylinders before shipment shall be Chevron Clarity Hydraulic Oils, AW ISO 32. 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.

2.6 Miscellaneous

The hydraulic cylinder rod eye, glands, flanges, cushions, bushings, bolts, nuts, washers, etc.

shall be made from a material selected from ERDC/CERL TR-02-7, Table 3 or from the finest selected quality materials as recommended by the Contractor subject to approval by the Contracting Officer. Rings, seals, bearings, bushings, packing, packing rings, retaining rings, fittings, etc. shall be made from the finest selected quality materials as recommended by the Contractor to provide zero leakage subject to approval by the Contracting Officer.

3.0 Shop Assembly and Testing

The hydraulic cylinder shall be completely shop assembled and tested insofar as is possible using temporary piping, etc. to determine the correctness of fabrication and acceptable operation as described in Section 2.3. 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 acceptance of the hydraulic cylinders will be made following delivery of the cylinders to the Troy Lock and Dam, and the completion of the final Government inspection that proves acceptability.

4.0 Fabrication and Maintenance Drawings

The Contractor shall provide fabrication drawings for all mechanical and structural parts or components except those which are of standard manufacture. A complete assembly drawing shall be provided to show where the components are to be located. The drawings shall show complete details of materials, tolerances, machined surface finishes, connections, and proposed welding sequences which differentiate shop welds and field welds. The maintenance drawings shall include a complete assembly and cross-section drawing of the hydraulic cylinder with parts list, and all information which may be needed or useful for operation, maintenance, repair, dismantling or assembling and for identification of parts for ordering replacements. All drawings shall be annotated to indicate any “as built” adjustments. A complete set of full size paper “as-built” drawings and their pdf files shall be provided.

5.0 Delivery, Storage and Handling

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 hydraulic cylinders. The hydraulic cylinders shall be filled with Chevron Clarity Oil, AW ISO 32 and the piping sealed. Internal rod supports shall be provided to prevent the rod from deflecting and damaging the rod and cylinder bore during handling and shipping. Machined surfaces shall be adequately protected from corrosion and physical damage. The hydraulic cylinders shall be delivered by the Contractor to the Troy Lock and Dam, 1 Bond Street, Troy, NY 12180, Monday through Friday between 0700 and 1500. 48 hours notice prior to delivery is required. The Contractor shall deliver the completed hydraulic cylinders to the Troy Lock and Dam no later than 90 days following contract award.

6.0 Warranty

The hydraulic cylinders shall be guaranteed for a period of two (2) years from the date of acceptance. Replacement parts shall be guaranteed for two (2) years from the date of replacement. Warranty shall be against defective materials, design and workmanship. In cases where the equipment manufacturer’s advertised minimum guarantee is in excess of two (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.

7.0 Liquidated Damages

(a) If the Contractor fails to complete the work within the time specified in the contract, the Contractor shall pay liquidated damages to the Government in the amount of $1,050.00 for each calendar day of delay until the work is accepted.

(b) If the Government terminates the Contractor’s right to proceed, liquidated damages will continue to accrue until the work is completed. These liquidated damages are in addition to excess costs of repurchase under the Termination clause.

8.0 Lump Sum Prices

Payment will be made for costs associated with the hydraulic cylinders as a lump sum. Such lump sum price shall include full compensation for all plant, labor, materials and supplies required to complete the work as shown on the plans and in accordance with the specifications.