35_05_40.14_10.pdf

St oney Gat e Val ve Repl acement 16033

HI RAM M. CHI TTENDEN LOCKS, SEATTLE, WA

SECTI ON TABLE OF CONTENTS

DI VI SI ON 35 - WATERWAY AND MARI NE CONSTRUCTI ON

SECTI ON 35 05 40. 14 10

HYDRAULI C POWER SYSTEMS FOR CI VI L WORKS STRUCTURES

05/14

PART 1 GENERAL

1. 1 SUMMARY

1. 2 REFERENCES

1. 3 DESI GN AND PERFORMANCE REQUI REMENTS

1. 3. 1 Desi gn Par amet er s

1. 3. 2 Al l owabl e St r esses

1. 3. 2. 1 St r uct ur al I t ems

1. 3. 2. 2 Hydr aul i c Cyl i nder s

1. 3. 2. 3 St r ess Concent r at i on Fact or s

1. 3. 3 Connect i ons

1. 3. 3. 1 Pi nned Connect i ons

1. 3. 3. 2 Shop Connect i ons

1. 3. 3. 3 Wel ded Connect i ons

1. 3. 3. 4 St r uct ur al Bol t ed Connect i ons

1. 4 SUBMI TTALS

1. 5 SCHEMATI C DRAWI NGS AND DATA

1. 5. 1 Shop Dr awi ngs

1. 5. 2 Fabr i cat i on Dr awi ngs

1. 5. 3 Hydr aul i c Power Uni t Dr awi ngs

1. 5. 4 Mani f ol d Dr awi ngs

1. 5. 5 Pi pi ng Dr awi ngs

1. 5. 6 El ect r i cal Dr awi ngs

1. 5. 7 Modi f i cat i on t o Exi st i ng Mi t er Gat e Cyl i nder Shut t l e Val ves

Control

1. 5. 8 Shop Assembl y Dr awi ngs

1. 5. 9 Hydr aul i c Schemat i c

1. 5. 10 Pr oduct Dat a

1. 5. 11 Del i ver y Dr awi ngs

1. 5. 12 Shop Assembl y and Test i ng Pr ocedur es and Resul t s

1. 5. 13 Fi el d I nst al l at i on Pr ocedur es

1. 5. 14 Desi gn and Per f or mance Cal cul at i ons

1. 5. 15 Cl eani ng and Fl ushi ng Pr ocedur es and Resul t s

1. 5. 16 Er ect i ng Engi neer Qual i f i cat i ons

1. 6 DELI VERY, STORAGE, AND HANDLI NG

1. 6. 1 Packagi ng

1. 6. 2 Shi ppi ng, Pr eser vat i on, and St or age

1. 7 WARRANTY

1. 8 QUALI TY CONTROL

PART 2 PRODUCTS

2. 1 MATERI ALS AND MECHANI CAL EQUI PMENT

2. 1. 1 Gener al

2. 1. 2 Hydr aul i c Cyl i nder s

2. 1. 2. 1 Cyl i nder Tubes

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2. 1. 2. 2 Cyl i nder Heads and Caps

2. 1. 2. 3 Pi st ons

2. 1. 2. 4 Pi st on Rods

2. 1. 2. 5 Cyl i nder Suppor t Assembl y and Tr unni on Mount

2. 1. 2. 6 Rod End Bear i ngs and Tr unni on Bear i ngs

2. 1. 2. 7 Connect i on Pi ns

2. 1. 2. 8 Bul khead Wat er Ti ght Seal

2. 1. 2. 9 Cyl i nder Mi scel l aneous Feat ur es

2. 1. 2. 10 Cyl i nder Nor mal Oper at i on St r oke and Bypass St r oke

2. 1. 2. 11 Cyl i nder Mai nt enance Sl i ngs

2. 1. 3 Hydr aul i c Power Uni t

2. 1. 4 Oi l Reser voi r s

2. 1. 4. 1 Reser voi r Heat er

2. 1. 4. 1. 1 Heat er Swi t ch

2. 1. 4. 1. 2 Hi gh Temper at ur e Swi t ch

2. 1. 4. 2 Magnet i c Separ at or s

2. 1. 4. 3 Low Level Fl oat Swi t ches

2. 1. 4. 4 Ai r Br eat her

2. 1. 4. 5 Oi l Level Gage

2. 1. 5 Pumps

2. 1. 6 Fi l t er s

2. 1. 7 Gauges

2. 1. 7. 1 Pr essur e Gauges

2. 1. 7. 2 Ther momet er

2. 1. 8 Mani f ol ds

2. 1. 9 Val ves

2. 1. 9. 1 Shut - Of f Val ves

2. 1. 9. 2 Sol enoi d Oper at ed Cont r ol Val ves

2. 1. 9. 2. 1 Pi l ot - Oper at ed, Sol enoi d- Cont r ol l ed Four - Way

Di r ect i onal Cont r ol Di r ect i onal

2. 1. 9. 3 Pr essur e Rel i ef Val ves

2. 1. 9. 4 Spr i ng Loaded Check Val ves

2. 1. 9. 5 Bl eeder Val ves

2. 1. 9. 6 Pr essur e Snubber s

2. 1. 9. 7 Load Hol di ng Val ves

2. 1. 10 Li mi t Swi t ches on Hydr aul i c Cyl i nder

2. 1. 11 Magnet ost r i ct i ve I nt egr al Cyl i nder Posi t i on Tr ansmi t t er

2. 1. 12 Pi pi ng

2. 1. 12. 1 Pi pe

2. 1. 12. 2 Pi pe Fi t t i ngs

2. 1. 12. 3 Pi pe and Tube Hanger s and Suppor t s

2. 1. 12. 4 Wal l Br acket s

2. 1. 12. 5 Uni ons

2. 1. 12. 6 Hydr aul i c Tubi ng

2. 1. 12. 7 Tube Fi t t i ngs

2. 1. 12. 8 Hose

2. 1. 13 Bol t s, Nut s, and Washer s

2. 1. 14 Hydr aul i c Fl ui d ( Pet r ol eum Based)

2. 1. 15 Housekeepi ng Pads

2. 1. 16 Dr i p Tr ays

2. 1. 17 Open Gr at i ng

2. 2 ELECTRI CAL EQUI PMENT

2. 2. 1 Cabi net s and Boxes

2. 2. 2 Pump Mot or s

2. 2. 2. 1 Rat i ng

2. 2. 2. 2 Wi ndi ng I nsul at i on

2. 2. 2. 3 Wi ndi ng Heat er s

2. 2. 2. 4 Ter mi nal Leads

2. 2. 3 Cont r ol Component s

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2. 2. 3. 1 Cont r ol Devi ces and Wi r i ng

2. 2. 3. 2 Pr essur e Swi t ches

2. 2. 3. 3 Pr essur e Tr ansducer s

2. 3 SHOP ASSEMBLY AND TESTI NG

2. 3. 1 Cyl i nder Test s

2. 3. 2 Hydr aul i c Power Uni t s

2. 4 MANUFACTURER PREPARATI ON BEFORE SHI PMENT

2. 4. 1 Fl ushi ng Hydr aul i c Cyl i nder s

2. 4. 2 Fl ushi ng Hydr aul i c Power Uni t

2. 5 PAI NTI NG

2. 6 SPECI AL TOOLS

2. 7 SPARE MECHANI CAL PARTS LI ST

PART 3 EXECUTI ON

3. 1 EXAMI NATI ON

3. 2 I NSTALLATI ON

3. 3 POWER PI PI NG

3. 3. 1 Pi pi ng I nst al l at i on

3. 3. 2 Pi pi ng Vent s and Dr ai ns

3. 3. 3 Mount i ng Suppor t f or Mani f ol ds

3. 4 CLEANI NG AND FLUSHI NG

3. 4. 1 Fl ushi ng Pi pi ng

3. 4. 2 Fl ushi ng Mani f ol ds and Hoses

3. 5 FI LLI NG AND BLEEDI NG THE SYSTEM

3. 6 ERECTI ON ENGI NEER

3. 7 FI ELD TESTS AND I NSPECTI ONS

3. 7. 1 Fi el d Test i ng

3. 7. 2 Pi pe Pr essur e Test

3. 7. 3 Pr epar at i on f or Fi el d Test s

3. 7. 3. 1 I ni t i al St ar t - Up

3. 7. 3. 2 Fi el d Test s

3. 7. 3. 2. 1 Manual Posi t i on Measur ement

3. 7. 3. 2. 2 Speed Schedul e Adj ust ment

3. 7. 3. 2. 3 Dr y Test

3. 7. 3. 2. 4 Lock Rewat er i ng Test

3. 7. 3. 2. 5 Nor mal Lock Navi gat i on Test

3. 7. 3. 2. 6 Mai nt enance Test

3. 7. 3. 2. 7 Fi l t er Car t r i dges

3. 7. 3. 3 Test Repor t s

3. 8 CLEAN- UP

3. 9 OPERATI ON AND MAI NTENANCE

- - End of Sect i on Tabl e of Cont ent s - -

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HYDRAULI C POWER SYSTEMS FOR CI VI L WORKS STRUCTURES

05/14

PART 1 GENERAL

1. 1 SUMMARY

Pr ovi de and i nst al l t he i ndi v i dual hydr aul i c syst ems t hat shal l act uat e al l cul ver t gat e val ves at t he Lake Washi ngt on Shi p Canal Chi t t enden Lock.

Test al l hydr aul i c power uni t s pr i or t o del i ver y. Cur r ent l y, al l t hr ee mi t er gat es on t he nor t h s i de of t he l ar ge l ocks ar e act uat ed wi t h a hydr aul i c syst em t hat i s l ocat ed i n mi ddl e machi ner y r ecess #2N.

Si mi l ar l y, al l t hr ee mi t er gat es on t he sout h s i de of t he l ar ge l ocks ar e act uat ed wi t h a hydr aul i c syst em t hat i s l ocat ed i n mi ddl e machi ner y r ecess #2S ( l ocat ed beneat h t he cont r ol t ower ) . No wor k i s r equi r ed f or t he mi t er gat e hydr aul i c syst ems, except t o modi f y t he el ect r i cal cont r ol s t o t he cyl i nder shut t l e val ves t o al l ow cont i nuousl y var i abl e cont r ol .

The wor k cover ed by t hi s sect i on of t he speci f i cat i ons consi st s of det ai l ed r equi r ement s f or t he desi gn, f abr i cat i on, shop assembl y, t est i ng, del i ver y, and i nst al l at i on of t he hydr aul i c power syst ems f or oper at i on of t he cul ver t val ves as speci f i ed and as shown.

1. 2 REFERENCES

The publ i cat i ons l i s t ed bel ow f or m a par t of t hi s speci f i cat i on. The publ i cat i ons ar e r ef er r ed t o wi t hi n t he t ext by t he basi c desi gnat i on onl y.

AMERI CAN WELDI NG SOCI ETY ( AWS)

AWS D1. 1/ D1. 1M ( 2015; Er r at a 1 2015; Er r at a 2 2016) St r uct ur al Wel di ng Code - St eel

ASME I NTERNATI ONAL ( ASME)

ASME B16. 11 ( 2011) For ged Fi t t i ngs, Socket - Wel di ng and Threaded

ASME B31. 1 ( 2016) Power Pi pi ng

ASME B36. 19M ( 2004; R 2015) St ai nl ess St eel Pi pe

ASME B40. 100 ( 2013) Pr essur e Gauges and Gauge Attachments

ASME BPVC SEC I X ( 2010) BPVC Sect i on I X- Wel di ng and Br azi ng Qualifications

ASME BPVC SEC VI I I D1 ( 2010) BPVC Sect i on VI I I - Rul es f or Const r uct i on of Pr essur e Vessel s Di v i s i on 1

ASTM I NTERNATI ONAL ( ASTM)

ASTM A182/ A182M ( 2016a) St andar d Speci f i cat i on f or For ged or Rol l ed Al l oy- St eel Pi pe Fl anges, For ged

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Fi t t i ngs, and Val ves and Par t s f or Hi gh- Temper at ur e Ser vi ce

ASTM A269/ A269M ( 2015a) St andar d Speci f i cat i on f or Seaml ess and Wel ded Aust eni t i c St ai nl ess St eel Tubi ng f or Gener al Ser vi ce

ASTM A312/ A312M ( 2016a) St andar d Speci f i cat i on f or Seaml ess, Wel ded, and Heavi l y Col d Wor ked Aust eni t i c St ai nl ess St eel Pi pes

ASTM A516/ A516M ( 2010; R 2015) St andar d Speci f i cat i on f or Pr essur e Vessel Pl at es, Car bon St eel , f or Moder at e- and Lower - Temper at ur e Ser vi ce

ASTM A519 ( 2006) St andar d Speci f i cat i on f or Seaml ess Car bon and Al l oy St eel Mechani cal Tubi ng

ASTM A536 ( 1984; R 2014) St andar d Speci f i cat i on f or Duct i l e I r on Cast i ngs

ASTM A564/ A564M ( 2013) St andar d Speci f i cat i on f or Hot - Rol l ed and Col d- Fi ni shed Age- Har deni ng St ai nl ess St eel Bar s and Shapes

ASTM A576 ( 1990b; R 2012) St andar d Speci f i cat i on f or St eel Bar s, Car bon, Hot - Wr ought , Speci al Quality

ASTM A705/ A705M ( 2013) St andar d Speci f i cat i on f or Age- Har deni ng St ai nl ess St eel For gi ngs

ASTM D3951 ( 2015) Commer ci al Packagi ng

ASTM F3125/ F3125M ( 2015, R A) St andar d Speci f i cat i on f or Hi gh St r engt h St r uct ur al Bol t s, St eel and Al l oy St eel , Heat Tr eat ed, 120 ksi ( 830 MPa) and 150 ksi ( 1040 MPa) Mi ni mum Tensi l e St r engt h, I nch and Met r i c Dimensions

I NTERNATI ONAL ORGANI ZATI ON FOR STANDARDI ZATI ON ( I SO)

I SO 1219- 1 ( 2012; Amd 1 2016) Fl ui d Power Syst ems and Component s Gr aphi c Symbol s and Ci r cui t Di agr ams - Par t 1: Gr aphi c Symbol s f or Convent i onal Use and Dat a- Pr ocessi ng Applications

I SO 1219- 2 ( 2012) Fl ui d Power Syst ems and Component s Gr aphi c Symbol s and Ci r cui t Di agr ams - Par t 2: Ci r cui t Di agr ams

I SO 4021 ( 1992) Hydr aul i c Fl ui d Power - Par t i cul at e Cont ami nat i on Anal ysi s - Ext r act i on of Fl ui d Sampl es f r om Li nes of an Oper at i ng System

I SO 4406 ( 1999) Hydr aul i c Fl ui d Power - Fl ui ds -

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Met hod f or Codi ng t he Level of Cont ami nat i on by Sol i d Par t i c l es

I SO 4407 ( 2002) Hydr aul i c Fl ui d Power - Fl ui d Cont ami nat i on - Det er mi nat i on of Par t i cul at e Cont ami nat i on by t he Count i ng Met hod Usi ng an Opt i cal Mi cr oscope

I SO 4413 ( 2010) Hydr aul i c Fl ui d Power — Gener al Rul es and Saf et y Requi r ement s f or Syst ems and Thei r Component s

I SO 5598 ( 2008) Fl ui d Power Syst ems and Component s

- Vocabul ar y

MANUFACTURERS STANDARDI ZATI ON SOCI ETY OF THE VALVE AND FI TTI NGS

I NDUSTRY ( MSS)

MSS SP- 58 ( 1993; Reaf f i r med 2010) Pi pe Hanger s and Suppor t s - Mat er i al s, Desi gn and Manuf act ur e, Sel ect i on, Appl i cat i on, and Installation

NATI ONAL ELECTRI CAL MANUFACTURERS ASSOCI ATI ON ( NEMA)

NEMA MG 1 ( 2016) Mot or s and Gener at or s

SOCI ETY OF AUTOMOTI VE ENGI NEERS I NTERNATI ONAL ( SAE)

SAE J514 ( 2012) Hydr aul i c Tube Fi t t i ngs

SAE J517 ( 2016) Hydr aul i c Hose

SAE J518- 1 ( 2013) Hydr aul i c Fl anged Tube, Pi pe, and Hose Connect i ons, 4- Scr ew Fl ange Connect i on Par t 1: 3. 5 MPa t o 35 MPa ( Code 61)

UNDERWRI TERS LABORATORI ES ( UL)

UL 50 ( 2015) UL St andar d f or Saf et y Encl osur es f or El ect r i cal Equi pment , Non- Envi r onment al Consi der at i ons

1. 3 DESI GN AND PERFORMANCE REQUI REMENTS

The cont r act dr awi ngs i ndi cat e t he gener al ar r angement of t he hydr aul i c power syst em f or oper at i on of t he cul ver t val ves, c l ear ances necessi t at ed by t he st r uct ur e or ot her equi pment , maxi mum over al l di mensi ons, and ot her per t i nent f eat ur es. Fur ni sh t he det ai l ed desi gn i n conf or mi t y wi t h I SO 4413, and t he f ol l owi ng desi gn cr i t er i a. I dent i f y desi gn and di mensi onal changes necessar y t o sat i sf y t he pr i nci pal desi gn par amet er s i dent i f i ed i n t he par agr aph DESI GN PARAMETERS ( bel ow) as var i at i ons i n t he submi t t al s. Di mensi ons submi t t ed t hat di f f er f r om t hose i ndi cat ed and not ot her wi se const r ai ned by t he Desi gn Par amet er s and physi cal l i mi t at i ons of i nst al l at i on ar e subj ect t o appr oval . Al so submi t desi gn comput at i ons f or al l f abr i cat i on and assembl y of t he hydr aul i c cyl i nder , hydr aul i c cyl i nder suppor t assembl y, cyl i nder connect i on pi n and bear i ng t o t he gat e and hydr aul i c power uni t s.

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The hydr aul i c hoi st suppl i er r esponsi bl e f or desi gni ng, f ur ni shi ng and commi ssi oni ng t he hydr aul i c hoi st s shal l be i n t he busi ness of f ur ni shi ng and i nst al l i ng gat e hydr aul i c syst ems and el ect r i c cont r ol of such equi pment f or no l ess t han 10 year s f r om t he cont r act awar d dat e. The hydr aul i c hoi st suppl i er shal l have at l east 5 wor ki ng gat e hydr aul i c i nst al l at i ons wi t h s i mi l ar or l ar ger s i ze and capaci t y whi ch have been i n oper at i on f or not l ess t han 5 year s f r om cont r act awar d dat e. The hydr aul i c hoi st desi gner shal l be a r egi st er ed Pr of essi onal Engi neer wi t h at l east 10 year s of exper i ence desi gni ng such equi pment . The el ect r i cal cont r ol s suppl i er shal l be a subcont r act or of t he hydr aul i c hoi st suppl i er . Mechani cal and st r uct ur al desi gn cr i t er i a shal l f ol l ow USACE EM 1110- 2- 2610 and ETL 1110- 2- 584.

1. 3. 1 Desi gn Par amet er s

Desi gn, f abr i cat e, and i nst al l s i x ( 6) i dent i cal cul ver t val ve hoi st s ( hydr aul i c power syst ems, hydr aul i c cyl i nder s, and hydr aul i c cyl i nder suppor t assembl y) . The Cont r act or i s r esponsi bl e f or t he pr oper desi gn and f unct i oni ng of t he equi pment i ncl udi ng t he hoi st suppor t syst em ( cyl i nder suppor t syst em and t r unni on) and t he f i nal desi gn f or connect i on t o t he gat e i ncl udi ng t he bear i ng and pi n s i ze. Accept abl e hoi st l ayout and f eat ur es shal l be as i ndi cat ed on t he cont r act dr awi ngs and as specified.

The Cont r act or shal l det er mi ne t he desi gn l oads and desi gn t he hoi st .

Load est i mat es and par amet er s ar e pr ovi ded f or bi ddi ng pur poses but t he Cont r act or i s r esponsi bl e f or cal cul at i ng t he hoi st l oads. Load est i mat es and par amet er s ar e as f ol l ows:

a. cul ver t val ve est i mat ed wei ght 16, 200 pounds

b. UHMWPE est i mat ed sl i di ng coef f i c i ent of f r i c t i on 0. 167

c. J- seal est i mat ed f r i ct i on 3000 pounds

d. 96, 668 l bf est i mat ed r ai s i ng ( l i f t i ng) cyl i nder f or ce based on f ul l wat er hei ght on one si de of gat e and no wat er on ot her s i de of gat e ( a dewat er ed condi t i on) . Thi s assumed 59, 523 l b f r i c t i on l oads mul t i pl i ed by 1. 25 f act or . To accompl i sh t hi s l i f t i ng f or ce, ut i l i ze a 2000 psi g wor ki ng pr essur e and i ncr ease pi st on r od si ze as necessar y.

e. 58, 140 l bf est i mat ed l ower i ng cyl i nder f or ce based agai n on a dewat er ed l ock condi t i on wi t h f ul l wat er head on one si de of t he gat e and i ncl udi ng 59, 523 l b f r i c t i on l oads wi t h a 1. 25 f act or . Cyl i nder shal l have a f act or of saf et y of 2 agai nst buckl i ng.

f . The hoi st syst em shal l be desi gned f or a maxi mum out put of 100, 000 l bf i n ei t her di r ect i on t o not exceed st r uct ur al l i mi t s of t he gat e and t he cyl i nder suppor t assembl y. Under t hi s condi t i on, st r uct ur al component s i ncl udi ng suppor t s shal l not exceed 75% of y i el d.

g. appl y f act or of saf et y of 5 f or cyl i nder component s i ncl udi ng suppor t s and connect i on pi n t o gat e f or a nor mal l ower i ng ( ext endi ng) f or ce( wor ki ng l oad) of 35, 000 l bs. Cyl i nder shal l have a f act or of saf et y of 3 agai nst buckl i ng.

The maxi mum oper at i onal l oad f or t hi s cul ver t val ve syst em occur s when i ni t i al l y f i l l i ng t he l ock af t er t he annual l ock dewat er i ng exer ci se.

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g3endnp9 Rectangle

For f i l l i ng t he l ock, t he cul ver t val ves ar e opened wi t h f ul l pool el evat i on on t he upst r eam si de and zer o wat er on t he downst r eam si de, 51 f eet of di f f er ent i al head. Est i mat ed l oads wer e cal cul at ed assumi ng wat er t o t he t op of t he l ock, or 55 f eet of di f f er ent i al head. Lock f i l l i ng may i ncl ude t he upper l ock, t he l ower l ock, or bot h t he upper and l ower l ocks. To f i l l t he upper l ock or bot h l ocks, wat er r out es f r om upst r eam of mi t er gat e 2 met er ed t hr ough t he cul ver t val ves 1N and 1S. To f i l l t he l ower l ock onl y, wat er r out es f r om upst r eam of mi t er gat e 3 t hr ough cul ver t val ves 2N and 2S. Nor mal oper at i onal l oads ar e due t o nor mal l ocki ng pr ocedur es bet ween upper pool and l ower pool el evat i ons. Nomi nal upper pool el evat i on i s 22 and nomi nal l ower pool r anges f r om el evat i on 14 ( hi gh wat er ) t o mi nus 4. 0 ( l ow wat er ) .

No component of t he hoi st equi pment shal l ext end above t he l ock wal l el evat i on 130. 0. No component shal l i nt er f er e wi t h t he r emovabl e deck pl at es on t he t op sur f ace of t he l ock wal l . Al l component s of t he hoi st equi pment shal l be i nst al l ed t hr ough exi st i ng r emovabl e deck pl at es i n t he t op sur f ace of t he l ock wal l .

The pr i nci pal desi gn par amet er s f or t he hydr aul i c power syst em ar e as follows:

a. Rai se and l ower speed vi a a 4- 20 MA cont r ol s i gnal bet ween 0. 0 f eet per mi nut e ( f pm) and 5. 60 f pm.

b. 34- i nch ( t o be ver i f i ed by Cont r act or ) maxi mum hoi st equi pment wi dt h ( access openi ng l i mi t at i on) .

c. 15. 0 f oot cyl i nder st r oke; 10- i nch cyl i nder bor e; 7- i nch cyl i nder r od di amet er , or as appr oved; ( 2: 1 ar ea r at i o di f f er ent i al cyl i nder ) .

d. r egener at i on c i r cui t f or cyl i nder ext end. Cyl i nder out put f or ce shal l not exceed 100, 000 pounds i n ei t her di r ect i on.

e. 2000 psi hydr aul i c desi gn oper at i ng ( wor ki ng) pr essur e.

Desi gn f eat ur e i s pr eci se aut omat i c cul ver t val ve speed cont r ol and pr eci se cyl i nder posi t i on sensi ng f or use by t he cont r ol syst em.

1. 3. 2 Al l owabl e St r esses

1. 3. 2. 1 St r uct ur al I t ems

The Cont r act or i s r esponsi bl e t o desi gn t he st r uct ur al i t ems associ at ed wi t h t hi s equi pment . St r uct ur al i t ems shal l be desi gned f or t he maxi mum ef f ect i ve hydr aul i c act uat or pr essur e, wi t h a mi ni mum f act or of saf et y of f i ve ( 5. 0) , based on t he ul t i mat e t ensi l e st r engt h of t he mat er i al . Al l component s shal l be desi gned f or a uni t st r ess not t o exceed 75% of t he y i el d st r engt h of t he mat er i al , usi ng t he maxi mum hydr aul i c act uat or pr essur e and f or ce avai l abl e t hr ough t he cont r ol syst em.

1. 3. 2. 2 Hydr aul i c Cyl i nder s

Desi gn al l hydr aul i c cyl i nder s t o wi t hst and a maxi mum oper at i ng pr essur e of 3000 psi wi t h a f act or of saf et y of 5 based on t he ul t i mat e st r engt h of t he mat er i al or 2 based on t he yi el d st r engt h of t he mat er i al . Appl y a f act or of saf et y of 3 t o t he compr essi on l oad when desi gni ng t he hydr aul i c cyl i nder s t o r esi st buckl i ng.

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1. 3. 2. 3 St r ess Concent r at i on Fact or s

Use st r ess concent r at i on f act or s wher e appl i cabl e. Reduct i on of al l owabl e st r esses t o compensat e f or r epeat ed cycl es of l oadi ng i s not r equi r ed.

1. 3. 3 Connections

1. 3. 3. 1 Pi nned Connect i ons

Desi gn pi nned hydr aul i c cyl i nder connect i ons f or f i el d assembl y as shown.

1. 3. 3. 2 Shop Connect i ons

Desi gn shop connect i ons f or assembl y by means of wel di ng or by bol t i ng.

1. 3. 3. 3 Wel ded Connect i ons

Desi gn wel ded connect i ons i n accor dance wi t h t he appl i cabl e pr ovi s i ons of AWS D1. 1/ D1. 1M except t hat pr ovi s i ons f or r epeat ed st r ess wi l l not be r equi r ed. Wel d hydr aul i c cyl i nder s i n accor dance wi t h ASME BPVC SEC VI I I D1, Sect i on VI I I . Wel d pi pi ng i n accor dance wi t h ASME B31. 1. Qual i f y pr ocedur es and wel der s i n accor dance wi t h ASME BPVC SEC I X. Wel di ng pr ocedur es qual i f i ed by ot her s, and wel der s and wel di ng oper at or s qual i f i ed by anot her empl oyer may be accept ed as per mi t t ed by ASME B31. 1. Not i f y t he Cont r act i ng Of f i cer 24 hour s i n advance of t est s and per f or m t he t est s at t he wor k s i t e i f pr act i cabl e.

Appl y t he wel der ' s or wel di ng oper at or ' s assi gned symbol near each wel d made as a per manent r ecor d. Submi t a copy of qual i f i ed pr ocedur es and a l i s t of names and i dent i f i cat i on symbol s of qual i f i ed wel der s and wel di ng operators.

1. 3. 3. 4 St r uct ur al Bol t ed Connect i ons

Make st r uct ur al bol t ed connect i ons car r y i ng pr i mar y l oads wi t h ASTM F3125/ F3125M bol t s.

1. 4 SUBMITTALS

Gover nment appr oval i s r equi r ed f or submi t t al s wi t h a " G" desi gnat i on;

submi t t al s not havi ng a " G" desi gnat i on ar e f or i nf or mat i on onl y. Submi t t he f ol l owi ng i n accor dance wi t h Sect i on 01 33 00 SUBMI TTAL PROCEDURES:

SD- 02 Shop Dr awi ngs

Schemat i c Dr awi ngs and Dat a; G

SD- 03 Pr oduct Dat a

Mat er i al s and Mechani cal Equi pment ; G

St andar d Pr oduct s; G

El ect r i cal Equi pment ; G

Hydr aul i c Cyl i nder Li mi t Swi t ches; G

I nt egr al Cyl i nder Posi t i on Tr ansmi t t er ; G

Modi f i cat i on To Mi t er Gat e Cyl i nder Shut t l e Val ve El ect r i cal

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Cont r ol s; G, ELE

Desi gn and Per f or mance Cal cul at i ons; G

Shop Assembl y and Test i ng Pr ocedur es; G

I nst al l at i on Pr ocedur es; G

Pi pi ng I nst al l at i on; G

Er ect i ng Engi neer Qual i f i cat i ons; G

Cl eani ng and Fl ushi ng; G

Fi el d Test i ng; G

Spar e Mechani cal Par t s Li st

SD- 06 Test Repor t s

Oper at i onal Test Repor t s; G

Shop Test s; G

Fi el d Test s; G

Pi st on Rods; G

SD- 10 Oper at i on and Mai nt enance Dat a

Oper at i on and Mai nt enance; G

1. 5 SCHEMATI C DRAWI NGS AND DATA

1. 5. 1 Shop Dr awi ngs

I ncl ude f abr i cat i on, shop assembl y, del i ver y, and f i el d i nst al l at i on dr awi ngs i n t he det ai l ed shop dr awi ngs. Det ai l any component par t of f abr i cat ed i t ems omi t t ed on t he shop dr awi ngs. I f depar t ur es f r om t he cont r act dr awi ngs ar e deemed necessar y by t he Cont r act or , submi t det ai l s of such depar t ur es, i ncl udi ng changes i n r el at ed por t i ons of t he pr oj ect and r easons t her eof , wi t h t he shop dr awi ngs.

1. 5. 2 Fabr i cat i on Dr awi ngs

Pr ovi de f abr i cat i on dr awi ngs f or al l mechani cal and st r uct ur al par t s or component s i ncl udi ng cyl i nder suppor t assembl y and connect i on assembl y t o t he gat e, except t hose whi ch ar e of st andar d manuf act ur e. The dr awi ngs must show compl et e det ai l s of mat er i al s, t ol er ances, machi ned sur f ace f i ni shes, connect i ons, and pr oposed wel di ng sequences whi ch di f f er ent i at e shop wel ds and f i el d wel ds. Pr ovi de det ai l ed dr awi ngs of t he dr i l l ed passages i n t he mani f ol ds.

1. 5. 3 Hydr aul i c Power Uni t Dr awi ngs

Pr ovi de dr awi ngs f or hydr aul i c power uni t s showi ng gener al ar r angement of component s and out l i ne di mensi ons. I dent i f y al l component s on t he dr awi ngs and pr ovi de suf f i c i ent i nf or mat i on t o det er mi ne whet her t he component s pr oposed conf or m t o t he speci f i cat i ons.

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1. 5. 4 Mani f ol d Dr awi ngs

Pr ovi de f abr i cat i on dr awi ngs f or al l mani f ol ds showi ng gener al ar r angement s out l i ne di mensi ons, and dr i l l i ng di mensi ons. I dent i f y al l component s on t he dr awi ngs and pr ovi de suf f i c i ent i nf or mat i on t o det er mi ne whet her t he component s pr oposed conf or m t o t he speci f i cat i ons. I dent i f y al l por t conf i gur at i ons and connect i ons.

1. 5. 5 Pi pi ng Dr awi ngs

Pr ovi de pi pi ng dr awi ngs showi ng t he compl et e hydr aul i c syst em i n schemat i c f or mat i dent i f y i ng al l i t ems of equi pment i ncor por at ed i n t he syst em.

I ncl ude det ai l s of al l pi pe suppor t s i ncl udi ng t hose f or mani f ol ds and on t he hydr aul i c power uni t .

1. 5. 6 El ect r i cal Dr awi ngs

Pr ovi de el ect r i cal dr awi ngs of al l el ect r i cal equi pment . On el ect r i cal dr awi ngs i ncl ude compl et e schemat i c di agr ams and connect i on di agr ams. On connect i on di agr ams show el ect r i cal connect i ons ( by l i nes) f or each conduct or bet ween t er mi nal poi nt s. I dent i f y t er mi nal poi nt s.

1. 5. 7 Modi f i cat i on t o Exi st i ng Mi t er Gat e Cyl i nder Shut t l e Val ves Cont r ol

The exi st i ng Bosch/ Rexr ot h mi t er gat e hydr aul i cs has a t wo st age st epped speed cont r ol t o t he cyl i nder shut t l e val ves. Thi s exi st i ng cont r ol shal l be modi f i ed usi ng r eadi l y avai l abl e el ect r i cal modul es f r om Bosch/ Rexr ot h t o al l ow cont i nuous speed cont r ol f r om a 4- 20 MA i nput s i gnal . Submi t on t he el ect r i cal modul es r equi r ed and wi r i ng di agr ams. The new cont r ol s shal l be abl e t o cont r ol t he cyl i nder speed f r om 5% t o 100%.

1. 5. 8 Shop Assembl y Dr awi ngs

Pr ovi de shop assembl y dr awi ngs wi t h det ai l s f or connect i ng t he adj oi ni ng f abr i cat ed component s i n t he shop t o ensur e sat i sf act or y f i el d installation.

1. 5. 9 Hydr aul i c Schemat i c

Pr ovi de a compl et e hydr aul i c schemat i c i n accor dance wi t h I SO 1219- 1 and I SO 1219- 2. Show al l hydr aul i c component s on t he schemat i c, and i ndi cat e al l set poi nt and si ze par amet er s f or each component .

1. 5. 10 Pr oduct Dat a

I ncl ude per f or mance dat a and cur ves f or pumps, mot or s and val ves. Pr ovi de cat al og cut s and out l i ne di mensi ons f or t he pumps, mot or s, f i l t er s, heat er s, t her most at s, f l oat swi t ches, pr essur e t r ansducer , swi t ches, br eat her s, and al l val ves, val ve cont r ol s and ot her accessories.

1. 5. 11 Del i ver y Dr awi ngs

Pr ovi de del i ver y dr awi ngs wi t h descr i pt i ons of met hods of del i ver i ng component s t o t he s i t e, i ncl udi ng det ai l s f or suppor t i ng f abr i cat ed component s dur i ng shi ppi ng t o pr event di st or t i on or ot her damage.

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1. 5. 12 Shop Assembl y and Test i ng Pr ocedur es and Resul t s

Pr ovi de pr ocedur es f or shop t est i ng and oper at i ng t est f or al l t est i ng out l i ned i n par agr aphs SHOP ASSEMBLY AND TESTI NG and FI ELD TESTS AND I NSPECTI ONS. Submi t oper at i onal t est r epor t s f or al l r equi r ed shop t est i ng and t est i ng of equi pment af t er i nst al l at i on. Pr ovi de r ecor ds of al l adj ust ment s and f i nal set t i ngs f or al l hydr aul i c component s i n t he syst em. Thi s i ncl udes pump f l ow r at es, oper at i ng t i mes, r el i ef set t i ngs, count er bal ance val ve adj ust ment s, oper at i ng pr essur es at bot h t he hydr aul i c power uni t s and cyl i nder mani f ol ds, f l ow l evel adj ust ment s, f i l t er di f f er ent i al swi t ch set t i ngs, and ot her par amet er s as out l i ned i n t he par agr aph TEST REPORTS.

1. 5. 13 Fi el d I nst al l at i on Pr ocedur es

Pr ovi de f i el d i nst al l at i on dr awi ngs wi t h a det ai l ed descr i pt i on of t he f i el d i nst al l at i on pr ocedur es. I ncl ude t he l ocat i on and met hod of suppor t of i nst al l at i on and handl i ng equi pment , t he pr ovi s i ons t o be t aken t o pr ot ect concr et e and ot her wor k dur i ng i nst al l at i on, t he met hod of mai nt ai ni ng component s i n cor r ect al i gnment , and t he met hods f or i nst al l i ng ot her appur t enant i t ems. I ncl ude dat es and schedul e of wor k.

Submi t met hods and pr ocedur es t o accel er at e t he sequence of wor k f or approval.

1. 5. 14 Desi gn and Per f or mance Cal cul at i ons

Pr ovi de desi gn cal cul at i ons f or al l i t ems whi ch ar e f ur ni shed by t he Cont r act or . Cal cul at i ons shal l i l l ust r at e pr oduct sel ect i ons f or al l hydr aul i c cyl i nder out put f or ces and speeds. Cal cul at i ons shal l i ncl ude:

oper at i ng pr essur e, el ect r i c power i nput , hydr aul i c syst em ef f i c i ency, seal f r i c t i on, UHMWPE sl i di ng f r i c t i on, l oads i n r ai se and l ower di r ect i ons, and ot her assumpt i ons. I ncl ude expect ed hydr aul i c power f l ow r at es and pr essur e r anges. I ncl ude hydr aul i c component model number s, and cat al og cut s. I ncl ude hydr aul i c schemat i c dr awi ng wi t h t ubi ng si zes and expect ed set poi nt s f or pr essur e r el i ef val ves and l oad hol di ng val ves.

I ncl ude hydr aul i c cyl i nder suppor t assembl y and t r unni on desi gn cal cul at i ons and t r unni on l ocat i on cal cul at i ons. Desi gn cal cul at i ons shal l be st amped by a r egi st er ed pr of essi onal engi neer . Pr ovi de t hr ee copi es of desi gn document at i on i n one compl et e document . Submi t as di gi t al and har dcopy f or mat . Pr ovi de t hr ee har dcopi es i n 3- r i ng bi nder

8. 5x11- i nch f or mat wi t h 11x17- i nch schemat i cs and dr awi ngs.

1. 5. 15 Cl eani ng and Fl ushi ng Pr ocedur es and Resul t s

Pr ovi de det ai l ed pr ocedur e f or t he c l eani ng and f l ushi ng of hydr aul i c cyl i nder s, pi pi ng, and power uni t as out l i ned i n par agr aph CLEANI NG AND FLUSHI NG, not l ess t han 30 days bef or e st ar t of oper at i ons. Pr ovi de t est r epor t s of t he r esul t s of t he f l ushi ng and of t he oi l used t o f i l l t he system.

1. 5. 16 Er ect i ng Engi neer Qual i f i cat i ons

Pr ovi de a r esume f or t he on- si t e er ect i ng engi neer wi t h det ai l s on exper i ence and backgr ound i n s i mi l ar i nst al l at i ons.

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1. 6 DELI VERY, STORAGE, AND HANDLI NG

1. 6. 1 Packaging

Do not pr epar e t he hydr aul i c power syst ems f or shi pment unt i l t hey have been i nspect ed and accept ed f or shi pment at or i gi n by t he Cont r act i ng Of f i cer , unl ess i nspect i on has been wai ved i n wr i t i ng. Shi p each hydr aul i c power syst em or subassembl y compl et el y assembl ed. The subassembl i es ar e def i ned as t he f ol l owi ng:

a. Hydr aul i c cyl i nder s. Each hydr aul i c cyl i nder subassembl y consi st s of t he hydr aul i c cyl i nder , cyl i nder suppor t assembl y and t r unni on, pi l l ow bl ock bear i ngs, bushi ngs, and cyl i nder suppor t pl at f or m.

b. Hydr aul i c power uni t s. Each hydr aul i c power uni t ( HPU) consi st s of r eser voi r , el ect r i c mot or , hydr aul i c pumps, di r ect i onal cont r ol val ves, r el i ef val ves, count er bal ance val ves, check val ves, i sol at i on val ves, pr essur e gauges, r eser voi r t emper at ur e and l evel swi t ches, pr essur e and r et ur n f i l t er s,

c. Pi pi ng assembl i es

d. Cont r ol consol es

Pr ovi de t he subassembl i es wi t h adequat e pr ot ect i ve pads, suppor t s, and bl ocki ng and secur el y r est r ai ned t o pr event di st or t i on or damage t o t he pai nt ed sur f aces i n t r ansi t . Any l oss or damage dur i ng shi pment , i ncl udi ng damage t o t he pai nt ed sur f aces, i s t he Cont r act or ' s r esponsi bi l i t y ; r epl ace or r epai r wi t hout cost t o t he Gover nment . Pack al l accessor i es and spar e par t s separ at el y i n cont ai ner s pl ai nl y mar ked " ACCESSORI ES ONLY, " or " SPARE PARTS ONLY. " Pl ace a packi ng l i s t , l i s t i ng t he cont ent s of each cont ai ner , i n a moi st ur e- pr oof envel ope and secur el y f ast en t o t he out si de of t he cont ai ner . St andar d commer ci al packagi ng i n accor dance wi t h ASTM D3951 wi l l be accept abl e except wher e a di f f er ent met hod or st andar d of packagi ng i s speci f i ed.

1. 6. 2 Shi ppi ng, Pr eser vat i on, and St or age

Packi ng, cr at i ng, cr adl es, et c. , necessar y t o ensur e saf e shi pment ar e t he r esponsi bi l i t y of t he Cont r act or and become t he pr oper t y of t he Gover nment upon del i ver y of t he equi pment . Submi t f or appr oval a pr ocedur e f or cont r ol l i ng movement of t he pi st on r od and t o pr event pi st on and cyl i nder damage dur i ng shi pment and handl i ng. Adequat el y pr ot ect machi ned sur f aces f r om cor r osi on and physi cal damage. Pr ot ect equi pment del i ver ed and pl aced i n st or age f r om t he weat her , humi di t y, t emper at ur e var i at i on, di r t and dust , or ot her cont ami nant s. Fur ni sh spar e cyl i nder wi t h a por t abl e pump, hose and connect i ons t o st r oke t he cyl i nder i n and out a shor t di st ance dur i ng st or age t o l ubr i cat e seal s and pr event damage.

1. 7 WARRANTY

Al l equi pment pr ovi ded shal l be guar ant eed wi t h an i ndust r y st andar d war r ant y. Pr ovi de War r ant y agai nst def ect i ve mat er i al s, desi gn, and wor kmanshi p. Upon r ecei pt of not i ce f r om t he Gover nment of f ai l ur e of any of t he par t s dur i ng t he war r ant y per i od, pr ovi de new r epl acement par t s pr ompt l y at no addi t i onal cost t o t he Gover nment .

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1. 8 QUALI TY CONTROL

Est abl i sh and mai nt ai n qual i t y cont r ol f or oper at i ons under t hi s sect i on t o assur e compl i ance wi t h cont r act r equi r ement s and mai nt ai n r ecor ds of qual i t y cont r ol f or al l mat er i al s, f abr i cat ed par t s, equi pment , and const r uct i on oper at i ons. I n addi t i on, est abl i sh and mai nt ai n sur vei l l ance f or qual i t y cont r ol over sub- cont r act or s, suppl i er s, or manuf act ur er s. The qual i t y cont r ol must i ncl ude a mi ni mum of t wo shop i nspect i ons dur i ng manuf act ur e and assembl y of t he hydr aul i c cyl i nder assembl i es power uni t s and mani f ol ds. The qual i t y cont r ol i ncl udes but i s not be l i mi t ed t o t he following:

a. Mat er i al s and wor kmanshi p.

b. Manuf act ur e and i nst al l at i on of t he pi pi ng, hydr aul i c cyl i nder assembl i es power uni t s and mani f ol ds, compl et e.

c. Cl eani ng and f l ushi ng.

d. Shop assembl y and t est s.

e. Fi el d er ect i on and t est s.

f . Damage and def ect s.

Fur ni sh a copy of t hese r ecor ds and t est s, as wel l as t he r ecor ds of cor r ect i ve act i on t aken, t o t he Gover nment .

PART 2 PRODUCTS

2. 1 MATERI ALS AND MECHANI CAL EQUI PMENT

2. 1. 1 General

Submi t dat a speci f i cat i ons and assembl y dr awi ngs showi ng si zes, r at i ngs, par t s and mat er i al l i s t s, over al l di mensi ons, and mount i ng di mensi ons wi t h t he pr oduct dat a. Al l syst em component s shal l have r at ed wor ki ng pr essur e at l east 2000 psi and r at ed maxi mum pr essur e at l east 3000 psi .

2. 1. 2 Hydr aul i c Cyl i nder s

Pr ovi de t he hydr aul i c cyl i nder t ypes l i s t ed i n I SO 5598, and speci f i ed or i ndi cat ed, of mi l l t ype desi gn, st andar d wel ded const r uct i on. Cyl i nder r od shal l be desi gned wi t h a mi ni mum f act or of saf et y of 3. 0 t o r esi st i ng buckl i ng under compr essi on. Pr ovi de evi dence t hat each cyl i nder was hydr ost at i cal l y t est ed by t he manuf act ur er t o 200 per cent of t he sever est ser vi ce r at i ng and t hat dynami c seal s ar e sui t abl e f or bot h f r equent and i nf r equent oper at i on and ar e capabl e of not l ess t han 500, 000 cycl es of oper at i on i n syst ems pr oper l y mai nt ai ned. Cont r act or shal l desi gn i nt er nal st op t ubes t o accommodat e s i de l oads due t o r equi r ed pi st on st r oke and ext end/ r et r act l oads.

Pr ovi de adj ust abl e cushi ons wi t h r ever se f r ee f l ow check val ves on bot h ends of t he cyl i nder s. Pr ovi de ai r bl eeds and oi l dr ai ns at bot h ends of t he cyl i nder s. Pr ovi de SAE Code 61 4 bol t hydr aul i c f l ange por t s.

Pr ovi de end st op el ect r i c l i mi t swi t ches and i nt er nal l y mount ed posi t i on t r acki ng sensor .

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2. 1. 2. 1 Cyl i nder Tubes

Machi ne t he cyl i nder t ube f r om ASTM A519, Gr ade 1018, heavy wal l seaml ess st eel t ubi ng and hone t he bor e t o a sur f ace f i ni sh compat i bl e wi t h t he seal s bei ng used so as t o r esul t i n zer o l eakage past t he seal s.

2. 1. 2. 2 Cyl i nder Heads and Caps

Fabr i cat e t he cyl i nder head and cap f r om ASTM A576, Gr ade 1018, st eel bar st ock or ASTM A516/ A516M, Gr ade 60 pl at e and machi ne f i ni sh on al l sur f aces. Al l cyl i nder s shal l be mi l l t ype. Equi p t he cyl i nder head wi t h a r od seal and ext er nal di r t wi per and a r od bushi ng pi l ot ed i nt o t he head t o ensur e concent r i c i t y. Rod bushi ngs must be r emovabl e wi t hout t he use of speci al t ool s and wi t hout r emovi ng t he cyl i nder head. Removabl e at t achment s must have t he cyl i nder t ube end seal s ar r anged t o seal wi t h pr essur e and be desi gned t o pr event shear i ng and ext r usi on and t o pr ovi de axi al met al backup.

2. 1. 2. 3 Pistons

Pr eci s i on f i t t he pi st on t o t he cyl i nder body bor e. The pi st on must be f i ne- gr ai ned cast i r on, desi gned and equi pped wi t h zer o l eakage cup- t ype seal s, or br onze- f i l l ed pol yt et r af l uor oet hyl ene seal s wi t h phenol i c wear r i ngs. The desi gn must pr ot ect t he pi st on r i ngs f r om bl ow- out and over squeezi ng. Cup- t ype seal s ( i f used) shal l be desi gned t o aut omat i cal l y compensat e f or wear .

2. 1. 2. 4 Pi st on Rods

Cyl i nder r ods shal l be chr ome- pl at ed st ai nl ess st eel . I f t he pi st on r od i s composed of t wo or mor e pi eces, r adi ogr aph al l wel ds. Conf or m t he st ai nl ess st eel t o ASTM A564/ A564M or ASTM A705/ A705M, Type 630 or Type XM- 12. Heat t r eat t o a condi t i on of H- 1150 bef or e f i nal machi ni ng. The f i nal r od sur f ace af t er chr ome pl at i ng must have a r oughness hei ght of not mor e t han 8 mi cr oi nch RMS wi t h chr ome pl at e t hi ckness 0. 003 i nch mi ni mum. Fur ni sh r od wi t h machi ned f l at s, or ot her det ai l ed met hod as appr oved t o r est r ai n r ot at i on dur i ng t hr eadi ng or unt hr eadi ng t he r od end bear i ng assembl y.

2. 1. 2. 5 Cyl i nder Suppor t Assembl y and Tr unni on Mount

The cyl i nder manuf act ur er i s r esponsi bl e t o desi gn t he cyl i nder suppor t assembl y and t r unni on mount , i ncl udi ng i t s l ocat i on on t he cyl i nder body and i ncl udi ng i t s bear i ngs as speci f i ed. Cont r act dr awi ngs i ndi cat e assembl y det ai l s f or a t ypi cal assembl y mount wi t h a l ocat i on t hat al l ows f or r od end access at t he bul khead seal , but assembl y mount has not been ot her wi se desi gned. Not e t hat t he cyl i nder t r unni on assembl y mount l ocat i on may be moved upwar d or downwar d f r om i t s i ndi cat ed l ocat i on as approved.

2. 1. 2. 6 Rod End Bear i ngs and Tr unni on Bear i ngs

Cont r act or shal l desi gn and f ur ni sh hydr aul i c cyl i nder r od end wi t h sel f - l ubr i cat i ng spher i cal pl ai n bear i ng and housi ng at t he cul ver t val ve connect i on. Fur ni sh cyl i nder t r unni on bear i ngs and cyl i nder mount pi l l owbl ock bear i ngs wi t h sel f - l ubr i cat i ng cyl i ndr i cal pl ai n bear i ng and axi al t hr ust bear i ngs. Dr awi ngs i ndi cat e f or bi ddi ng pur poses a spher i cal pl ai n bear i ng at r od end shal l have 5- i nch di amet er bor e, st at i c l oad capaci t y at l east 800, 000 pounds and dynami c l oad capaci t y at l east

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400, 000 pounds. Cont r act or shal l r evi ew and pr ovi de f i nal desi gn of t hese component s. Bear i ng mount s and pi ns shal l be s i zed and conf i gur ed t o f i t t he appr oved bear i ng i n accor dance wi t h t he bear i ng manuf act ur er ' s r ecommendat i ons. Spher i cal pl ai n bear i ngs, t r unni on bear i ngs, pi l l owbl ock bear i ngs, and t hr ust bear i ngs shal l be sel ect ed as speci f i ed i n 35 05 40. 17

SELF- LUBRI CATED MATERI ALS, FABRI CATI ON, HANDLI NG, AND ASSEMBLY.

2. 1. 2. 7 Connect i on Pi ns

Fabr i cat e cul ver t val ve connect i on pi ns f r om ASTM A564/ A564M, Type 630, Condi t i on H- 1150, st ai nl ess st eel . Pr ovi de 1. 0- UNC t hr eaded t hr eaded bor es 2. 0- i nches deep on each end of t he connect i on pi n t o ai d i n r emoval .

2. 1. 2. 8 Bul khead Wat er Ti ght Seal

Desi gn and f ur ni sh f l exi bl e wat er seal syst em t o f i t over cyl i nder r od.

Bul khead seal syst em shal l be desi gned t o mi ni mi ze l ock chamber wat er l eakage i nt o t he oper at i ng machi ner y r oom. The bul khead seal syst em at t he hydr aul i c cyl i nder shal l i ncl ude t he desi gn f eat ur es i ndi cat ed on t he cont r act dr awi ngs. Bul khead seal syst em i ncl udes mul t i pl e f l exi bl e f l anged pi pi ng connect i ons wi t h l at er al compl i ance t o accommodat e cul ver t val ve mot i ons and not i mpar t damagi ng si de l oads t o t he t r unni on mount ed hydr aul i c cyl i nder . The bul khead seal syst em i s al so desi gned t o pr ovi de a secondar y cont ai nment f or acci dent al f l ui d l eaks f r om t he hydr aul i c cyl i nder r od seal s. The bul khead seal i s al so desi gned so i t can be r ai sed up t o pr ovi de access t o t he cul ver t val ve connect i on pi n. Syst em shal l i ncl ude st uf f i ng box assembl y wi t h adj ust abl e seal packi ng mount ed on t he mul t i pl e f l exi bl e f l anged pi pi ng expansi on j oi nt s. St uf f i ng box packi ng seal mat er i al shal l be l ubr i cat ed PTFE- i mpr egnat ed ar ami d f i ber as appr oved.

2. 1. 2. 9 Cyl i nder Mi scel l aneous Feat ur es

Hydr aul i c component s schemat i cal l y i ndi cat ed on t he cyl i nder s i de of t he f l exi bl e hoses shal l be mount ed at t he cap end of t he cyl i nder ( above el evat i on 123. 0 as i nst al l ed) t o be accessi bl e at el evat i on 123. 0.

Cyl i nder posi t i on sensi ng shal l i ncor por at e i nt er nal pr obe i nst al l ed t hr ough t he r od end of t he cyl i nder . Cyl i nder adj ust abl e end cushi ons shal l i ncor por at e el ect r i c end st op l i mi t swi t ches r edundant t o ot her posi t i on sensi ng mechani sms.

Pr ovi de l i f t eye at cyl i nder cap end f or hoi st i ng hydr aul i c cyl i nder assembl y dur i ng i nst al l at i on and r emoval . Li f t eye shal l be desi gned so i t s use does not i nt er f er e wi t h t he posi t i on sensi ng pr obe al so i nst al l ed t hr ough t he cyl i nder cap end.

2. 1. 2. 10 Cyl i nder Nor mal Oper at i on St r oke and Bypass St r oke

For nor mal l ock oper at i on, cul ver t val ve r ai sed posi t i on i s 168- i nches above cul ver t val ve c l osed posi t i on. Cyl i nder st r oke f or nor mal l ock oper at i on shal l be 168- i nches. Nor mal oper at i on up and down posi t i ons wi l l be cont r ol l ed by t he cul ver t val ve posi t i on sensi ng syst em.

Cyl i nder bypass mode st r oke shal l exceed t he nor mal oper at i on st r oke i n bot h di r ect i ons. Cyl i nder shal l be l ess t han f ul l y ext ended i n cul ver t val ve nor mal oper at i on c l osed posi t i on. Cyl i nder shal l be l ess t han f ul l y r et r act ed i n cul ver t val ve nor mal oper at i on open posi t i on. Pr ovi de bypass mode cyl i nder st r oke at l east 180- i nches f or access t o cul ver t val ve

SECTI ON 35 05 40. 14 10 Page 16 connect i on pi n above bul khead st r uct ur e.

Cyl i nder maxi mum r et r act posi t i on shal l be enabl ed i n bypass oper at i on mode t o hoi st t he cul ver t val ve connect i on pi n cent er l i ne t o at l east el evat i on 105. 5. Cyl i nder maxi mum r et r act posi t i on as i nst al l ed shal l not r esul t i n cont act bet ween t he cul ver t val ve and t he bul khead st r uct ur e.

2. 1. 2. 11 Cyl i nder Mai nt enance Sl i ngs

The cul ver t val ve desi gn i ncl udes t wo mai nt enance l i f t eyes on cul ver t val ve t op sur f ace and t wo mai nt enance l i f t eyes anchor ed t o t he concr et e wal l s. The mai nt enance l i f t eyes ar e i nt ended t o suspend t he cul ver t val ve wi t h t he cyl i nder r emoved and wi t h t he cul ver t val ve cyl i nder r od end l i f t eyes r ai sed compl et el y above t he bul khead pl at e t op sur f ace.

Fur ni sh t wo l i nk chai n s i ngl e l eg s l i ngs usi ng Gr ade 70 l i nk chai n and wi t h sui t abl e end at t achment s and l engt hs as appr oved t o at t ach t o t he mai nt enance l i f t eyes and suspend t he cul ver t val ve. Each sl i ng shal l i ncor por at e an eye and j aw r at chet t ur nbuckl e ( Pat t er son model number 1- 3/ 8 x 12 Type DJ or as appr oved) at t he cul ver t val ve end at t achment t o al l ow at l east ( +/ - ) 3- i nch l engt h adj ust ment f r om t he appr oved sl i ng l engt h. Each sl i ng assembl y saf e wor ki ng l oad shal l be at l east 17000 pounds. Requi r ed el evat i ons ar e i ndi cat ed on t he cont r act dr awi ngs.

2. 1. 3 Hydr aul i c Power Uni t

Fur ni sh and i nst al l s i x ( 6) i dent i cal i nt er changeabl e hydr aul i c power uni t s each mount ed i ndoor s at el evat i on 123. 0 f eet adj acent t o t he r espect i ve cyl i nder s as i ndi cat ed on t he cont r act dr awi ngs. Pr ovi de hydr aul i c power uni t s desi gned by t he Cont r act or t o oper at e t he hydr aul i c cyl i nder s i n accor dance wi t h t he cr i t er i a st at ed i n par agr aph DESI GN PARAMETERS. Desi gn t he power uni t t o meet t he space l i mi t at i ons shown and conf i gur e as speci f i ed. Al l equi pment shal l be r emoved and i nst al l ed t hr ough t he r emovabl e f l oor pl at es at out door s t op of l ock el evat i on

130. 0. The openi ngs at t he f l oor pl at es ar e appr oxi mat el y 34- i nches wi de. The Cont r act or i s r esponsi bl e t o i dent i f y l i mi t i ng di mensi ons t o ensur e al l equi pment can be i nst al l ed t hr ough t hese f l oor pl at e openi ngs.

To ai d i nst al l at i on and f ut ur e mai nt enance, desi gn t he hydr aul i c power uni t r eser voi r and at t ached equi pment wi t h over head l i f t i ng eyes on t op and f or kl i f t t ubes under neat h. The st r uct ur e of t he uni t bot h i nt er nal l y and ext er nal l y must be adequat e f or t he uni t t o be f r ee st andi ng and capabl e of bei ng l i f t ed or moved wi t hout st r uct ur al damage. Secur el y at t ach al l component s i ncl udi ng pi pi ng, mot or s, pumps and mani f ol ds t o t he power uni t i n a manner t o be f r ee of damagi ng vi br at i on dur i ng oper at i on.

The hydr aul i c cont r ol c i r cui t i ndi cat ed i ncl udes r egener at i on check val ve and a 2: 1 cyl i nder bor e ar ea t o pi st on r od ar ea r at i o. These i t ems al l ow t hat t he di r ect i onal f l ow cont r ol val ve f l ow r ange i s t he same bot h di r ect i ons and l i mi t s maxi mum syst em pr essur e dur i ng cyl i nder ext end motion.

2. 1. 4 Oi l Reser voi r s

Si ze t he oi l r eser voi r t o hol d at l east 50 gal l ons and al so t o meet t he space l i mi t at i ons i ndi cat ed. Make t he r eser voi r of st ai nl ess st eel wi t h wel ded j oi nt s and conf or m t o t he r equi r ement s as shown. The r eser voi r s must conf or m t o t he r equi r ement s of I SO 4413. Pr ovi de a mount i ng base on t he r eser voi r whi ch suppor t s t he associ at ed val ves and accessor i es f or desi gn l oads and speeds. To f aci l i t at e dr ai nage, t he bot t om of t he r eser voi r must have a mi ni mum cl ear ance f r om t he f l oor of not l ess t han 12

SECTI ON 35 05 40. 14 10 Page 17 i nches. Sl ope t he r eser voi r bot t om sur f aces downwar ds t owar ds dr ai n por t ( s) t o al l ow compl et e dr ai ni ng of t he r eser voi r t hr ough t he dr ai n por t s. The pump i nl et l i ne shal l i ncl ude a f oot val ve or check t o pr ovi de f l ooded pump suct i on. Pr ovi de each si de of t he r eser voi r wi t h a c l eanout openi ng of not l ess t han 400 squar e i nches cl ear ance wi t h a bol t ed, gasket ed cover . Pr ovi de each r eser voi r wi t h a dr ai n wi t h shut - of f val ve;

a magnet i c t r ap; l ow oi l f l oat l evel swi t ches; and ot her appur t enances as i ndi cat ed and as speci f i ed her ei n. Equi p t he r eser voi r wi t h a f l ui d l evel i ndi cat or and f i l l er wi t h bui l t - i n st r ai ner . Pr ovi de a baf f l e bet ween t he i nt ake and r et ur n l i nes t o f aci l i t at e t he separ at i on of ai r and f or ei gn mat t er f r om t he hydr aul i c f l ui d. The connect i on bet ween t he t wo chamber s of t he r eser voi r must be hi gh enough f r om t he bot t om t o f or m a set t l i ng chamber . Br i ng bot h t he i nt ake and r et ur n pi pes down t o a di st ance of 1- 1/ 2 pi pe di amet er s above t he t ank bot t om. Wel ded j oi nt s of t he r eser voi r shal l be smoot h and f r ee f r om i r r egul ar i t i es. Unt i l f i nal i nst al l at i on of t he hydr aul i c equi pment , seal al l openi ngs wi t h pl ast i c c l osur es. Cont r act or i s r esponsi bl e t o det er mi ne t he r eser voi r f l ui d capaci t y as appr oved. Anchor t he r eser voi r s t o t he concr et e by sui t abl e anchor bol t s. Fur ni sh al l pi pi ng, f i t t i ngs, hose, mani f ol d bl ocks, f ast ener s and appur t enances r equi r ed t o connect equi pment t o t he r eser voi r .

2. 1. 4. 1 Reser voi r Heat er

Pr ovi de r eser voi r s wi t h one or mor e dr y wel l t ype i mmer si on heat er s wi t h f l exi bl e heat i ng el ement s wi t h a wat t densi t y not t o exceed 11 wat t s per squar e i nch. I ncl ude a t her most at set t o mai nt ai n t he hydr aul i c oi l at 40 degr ees F. The desi gn shal l f aci l i t at e easy r emoval of t he heat er wi t hout dr ai ni ng t he t ank cont ent s. Fabr i cat e t he heat er sheat h and scr ew pl ug f r om st ai nl ess st eel . Heat er el ement s and j unct i on box shal l be wat er t i ght expl osi on r esi st ant st ai nl ess st eel , NEMA 4X. Pr ovi de a weat her pr oof j unct i on box wi t h a s i ngl e phase, 120 vol t , cont r ol t r ansf or mer f or t he t her most at and hi gh t emper at ur e c i r cui t .

2. 1. 4. 1. 1 Heat er Swi t ch

Pr ovi de a t her most at t o sense t he oi l t emper at…