Amend-0002_Section_41_24_27.10_28.pdf

Lucky Peak Outlet Slide Gate Hydraulic Cylinder Rehab W912EF18Q0023

SECTION TABLE OF CONTENTS

DIVISION 41 - MATERIAL PROCESSING AND HANDLING EQUIPMENT

SECTION 41 24 27.10 28

RECONDITIONING OF HYDRAULIC CYLINDERS

PART 1 GENERAL

1.1 SCOPE

1.2 REPAIR FACILITY QUALIFICATIONS

1.3 REFERENCES

1.4 SUBMITTALS

1.5 WELDER QUALIFICATIONS

1.6 LEAD BASED PAINT

1.7 DELIVERY, STORAGE, AND HANDLING

1.7.1 Packaging

1.7.2 Shipping, Preservation, and Storage

1.8 WARRANTY

PART 2 PRODUCTS

2.1 STANDARD PRODUCTS

2.2 MATERIALS AND MECHANICAL EQUIPMENT

2.2.1 Existing Hydraulic Cylinder

2.2.1.1 Existing Cylinder Shell

2.2.1.2 Existing Cylinder Flanges

2.2.1.3 Cylinder Head

2.2.1.4 Existing Bonnet Cover

2.2.1.5 Bonnet Cover Glands

2.2.1.6 Sealant

2.2.1.7 Packing

2.2.1.8 "O"-Rings

2.2.1.9 Cylinder Studs

2.2.1.10 Cylinder Stud Nuts

2.2.1.11 Existing Piston

2.2.1.12 Piston Rings

2.2.1.13 Existing Piston Rod

2.2.2 Hydraulic Fluid

2.2.3 Ball Valves

2.2.4 Bonnet Cover Studs

2.2.5 Bonnet Cover Stud Nuts

2.2.6 Slide Gate Stem Nut Access Plate Cap Screws

2.2.7 Bulkhead Slot Cover Plate Gasket

2.2.8 Hydraulic Piping

2.2.8.1 Pipe

2.2.8.2 Pipe Fittings

2.3 SILVACEL PIPING

2.3.1 Identification and Tagging

2.3.2 Stainless Steel Pipe

2.3.3 Stainless Steel Grooved Fittings and Couplings

2.4 Support Bolts

2.5 SHOP PAINTING

PART 3 EXECUTION

SECTION 41 24 27.10 28

3.1 GENERAL

3.2 HYDRAULIC CYLINDER REMOVAL AND REINSTALLATION

3.2.1 Cylinder Removal

3.2.2 Cylinder Installation

3.2.3 Cylinder Removal and Reinstallation Procedures

3.3 HYDRAULIC CYLINDER RECONDITIONING

3.3.1 General

3.3.2 Disposal of Used Hydraulic Fluid

3.3.3 Cylinder Exterior

3.3.4 Packings, Seals, and Fasteners

3.3.5 Cylinder Interior

3.3.6 Piston Rod

3.3.7 Piston and Piston Rings

3.3.8 Cylinder Head

3.3.9 Bonnet Cover and Glands

3.3.10 Reassembly

3.4 CYLINDER INTERIOR DEFECT REPAIR

3.5 BONNET COVER REPAIR

3.6 SHOP TESTS

3.6.1 Initial Hydrostatic Tests

3.6.2 Final Hydrostatic Tests

3.7 FIELD TESTS AND INSPECTIONS

3.7.1 Filling and Bleeding the System

3.7.2 Final Acceptance Tests

3.7.2.1 Dry Test

3.7.2.2 Wet Test

3.8 FIELD TOUCH UP PAINTING

-- End of Section Table of Contents --

SECTION 41 24 27.10 28

g4edddca Line g4edddca Line

RECONDITIONING OF HYDRAULIC CYLINDERS

PART 1 GENERAL

1.1 SCOPE

This section covers reconditioning of the outlet slide gate hydraulic cylinders located in the outlet structure at Lucky Peak Project. Provide all supervision, labor, materials, plant, and equipment to perform the specified work. There are six outlet slide gates and associated hydraulic cylinders paired with three hydraulic power systems. There are only two isolation bulkheads that are used to allow the slide gates to be taken out of service. See the For Information Only drawings for details of the existing slide gates and hydraulic cylinders. It has been observed that cylinder 4 has some leakage of hydraulic fluid to the environment.

1.2 REPAIR FACILITY QUALIFICATIONS

Hydraulic cylinder repair must be performed at and by a facility that has had previous experience in the manufacture or repair of hydraulic cylinders with inside diameter of 24" to 36" and stroke of 10' and testing at 1500 psig or more. Submit documentation demonstrating that the repair facility meets this requirement.

1.3 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.

ASME INTERNATIONAL (ASME)

ASME B16.11 (2011) Forged Fittings, Socket-Welding and Threaded

ASME B31.1 (2014; INT 1-47) Power Piping

ASME B31.9 (2014) Building Services Piping

ASME BPVC SEC IX (2010) BPVC Section IX-Welding and Brazing Qualifications

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM A106/A106M (2014) Standard Specification for Seamless Carbon Steel Pipe for High-Temperature Service

ASTM A193/A193M (2015a) Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service and Other Special Purpose Applications

ASTM A234/A234M (2013; E 2014) Standard Specification for

Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature Service

ASTM A312/A312M (2015) Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes

ASTM A351/A351M (2014) Standard Specification for Castings, Austenitic, for Pressure-Containing Parts

ASTM A403/A403M (2015) Standard Specification for Wrought Austenitic Stainless Steel Piping Fittings

ASTM A743/A743M (2013a; E 2014) Standard Specification for Castings, Iron-Chromium, Iron-Chromium-Nickel, Corrosion Resistant, for General Application

ASTM F593 (2013a) Stainless Steel Bolts, Hex Cap Screws, and Studs

ASTM F594 (2009; E 2011) Standard Specification for Stainless Steel Nuts

ASTM F879 (2015) Stainless Steel Socket Button and Flat Countersunk Head Cap Screws

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 10763 (1994) Hydraulic Fluid Power - Plain-end, Seamless and Welded Precision Steel Tubes

- Dimensions and Nominal Working Pressures

ISO 4406 (1999) Hydraulic Fluid Power - Fluids - Method for Coding the Level of Contamination by Solid Particles

1.4 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals having an "I" designation are for information only. When used, a designation following the "G" or "I" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Repair Facility Qualifications; G C

Cylinder Removal Schedule; G C

Cylinder Installation Schedule; G C

Handling Procedures; I C

Submit step-by-step procedures for the removal and reinstallation of the hydraulic cylinders and isolation bulkheads.

Welder Qualifications; G C

Submit information for welders and welding operators at least 30 days prior to performing the work specified. Include qualified procedures and a list of names and identification symbols of welders and welding operators including support data such as test procedures used, standards tested to, etc.

Submit Shop Test Schedules at least 14 days prior to the start of related testing. Identify the date, time, and location for each test.

Initial Hydrostatic Test Schedules; G C

Final Hydrostatic Test Schedules; G C

Field Test Schedules; G C

Submit Field Test Schedules at least 14 days prior to the start of related testing. Identify the date and time for each test.

Coordinate with the Contracting Officer's Representative while preparing the Field Test Schedules.

SD-02 Shop Drawings

Submit shop drawings that include all shop and erection details, templates, fabrication and installation details, tolerances, type, grade and class of materials, as appropriate. Drawings shall consist of plans drawn to scale, with elevations and sections to show clearly the location (by dimension to pertinent outlet structure features) and routing of piping, including but not limited to; details of connections and size and type of piping, all support types and locations, and appurtenances. Show all materials of construction and all bolted and welded connections. Members and connections for any portion of the elements of fabricated items omitted from the Contract drawings shall be detailed by the fabricator and indicated on the shop drawings.

Bonnet Cover Glands; I ME

Cylinder Studs; I ME

Cylinder Stud Nuts; I ME

Bonnet Cover Studs; I ME

Bonnet Cover Stud Nuts; I ME

Bulkhead Slot Cover Plate Gasket; I ME

Piston Rings; I ME

Silvacel Piping; I ME

SD-03 Product Data

Include manufacturer's catalog data and descriptive literature for all equipment and products to be incorporated in the work. Include manufacturer's descriptive and technical literature; catalog cuts;

performance charts and curves; installation instructions, and assembly drawings showing sizes, ratings, parts and material lists, overall dimensions, and mounting dimensions. Include a list of any special tools necessary for the adjustment, operation, maintenance, and disassembly of the equipment.

Bonnet Cover Glands; I ME

Sealant; I ME

Packing; I ME

"O"-Rings; I ME

Cylinder Studs; I ME

Cylinder Stud Nuts; I ME

Bonnet Cover Studs; I ME

Bonnet Cover Stud Nuts; I ME

Slide Gate Stem Nut Access Plate Cap Screws; I ME

Piston Rings; I ME

Ball Valves; I ME

Bulkhead Slot Cover Plate Gasket; I ME

Hydraulic Piping; I ME

Silvacel Piping; I ME

SD-06 Test Reports

Submit test reports for all Shop and Field tests. Include certified calibration reports of all test instrumentation. Include in calibration reports certification that all test instrumentation has been calibrated within 6 months prior to the test date, identification of all instrumentation, and certification that all instrumentation complies with requirements of the test standard. Document all phases of tests performed. Include initial test summaries, all repairs/adjustments made, and the final test results.

Initial Hydrostatic Test Reports; I ME

Final Hydrostatic Test Reports; G ME

Field Test Reports; G ME

SD-11 Closeout Submittals

Warranty; I C

1.5 WELDER QUALIFICATIONS

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's Representative 24 hours in advance of tests.

1.6 LEAD BASED PAINT

Lead paint tests done on the cylinders and appurtenances were positive for the presence of lead based paint. The isolation bulkhead slot cover plate fasteners are coated with lead based paint, but tests done on the cover plates indicates they are not coated with lead based paint. Follow the procedures for worker hygiene during removal and installation work as specified in Section 01 57 20.00 28 ENVIRONMENTAL PROTECTION.

1.7 DELIVERY, STORAGE, AND HANDLING

1.7.1 Packaging

After the cylinders have been disconnected and removed from the slide gates and during the period prior to reinstallation on the slide gates, handle and transport the cylinders in a manner to prevent any cylinder damage.

Handle the cylinders at all times in a manner to prevent entry of foreign materials. Provide adequate protective pads, supports, blocking, and securely restrain 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 must be replaced or repaired without additional cost to the Government.

1.7.2 Shipping, Preservation, and Storage

Fill the hydraulic cylinder with the specified hydraulic fluid and seal the piping connections prior to returning the cylinder. Shipping provisions must allow the cylinder to be rotated in increments of 90 degrees during storage. Should the cylinder be stored by the Contractor in the horizontal position for more than 30 days, rotate the cylinder every 30 days as follows: first 90 degrees, then 180 degrees, then 90 degrees, and then 180 degrees. Adequately protect painted and 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

Provide a warranty against defective new materials and workmanship for a period of 1 year from the date of acceptance. Provide a warranty for replacement of new parts for a period of 1 year from date of replacement.

Upon receipt of notice from the Government of failure of any of the new parts and workmanship during the warranty period, furnish and install new replacement parts promptly at no additional cost to the Government.

PART 2 PRODUCTS

2.1 STANDARD PRODUCTS

Provide materials and equipment that conform to the requirements indicated or specified, and if not specified, furnish materials and equipment of the best commercial grade quality suited for the intended use. Such materials and equipment must be the standard products of a manufacturer regularly engaged in the manufacture of the products and that essentially duplicate items that have been in satisfactory use for at least 2 years prior to bid opening. Items of the same classification are to be identical, including equipment, assemblies, parts, and components.

Where items are referred to hereinafter as equal to a particular manufacturer's product, such references have been made merely as a convenient method of indicating the type of material or equipment required, with no intention of asserting superiority thereof. The standard product of any reputable manufacturer regularly engaged in the commercial production of the type and quality of material or equipment referred to will not be excluded on the basis of minor differences, provided essential requirements of the specifications relative to materials, capacity, and performance are met.

2.2 MATERIALS AND MECHANICAL EQUIPMENT

2.2.1 Existing Hydraulic Cylinder

See the For Information Only drawings for details of the existing cylinders and the materials used in their construction.

2.2.1.1 Existing Cylinder Shell

Cylinder shells are made of ASTM A212-52T, Grade B, firebox quality steel.

Any weld rod used to make repairs to the shell must be compatible with this material.

2.2.1.2 Existing Cylinder Flanges

Cylinder flanges are made of forged steel meeting ASTM A105-46, Grade I.

Any weld rod used to make repairs to the flanges must be compatible with this material.

2.2.1.3 Existing Cylinder Head

Cylinder heads are made of cast steel meeting ASTM A216-47T, Grade WCB.

Any weld rod used to make repairs to the cylinder head must be compatible with this material.

2.2.1.4 Existing Bonnet Cover

Bonnet covers are made of cast steel meeting Federal Specification QQ-S-681b, Class 2. Any weld rod used to make repairs to the bonnet cover must be compatible with this material.

2.2.1.5 Bonnet Cover Glands

The existing bonnet cover glands are made of cast bronze meeting Federal Specification QQ-B-691b, composition 6. If new glands are required, furnish and install new glands made of material with equivalent or better mechanical properties.

2.2.1.6 Sealant

Furnish and install a non-sag, single component, polyurethane sealant specifically developed for marine environments that will cure on exposure to atmospheric moisture and form a durable elastomer suitable for bonding to metals and painted surfaces. Sealant must be elastic, resistant to aging and weathering, non-corrosive, and resistant to fresh water.

2.2.1.7 Packing

Existing packings are Garlock Chevron number 430, 431, or 432. Furnish and install new Chevron or V-type packing made of material with equivalent or better mechanical properties and compatible with the hydraulic fluid used in the system. Provide material that when left in stationary contact with steel and bronze parts for long periods, will not result in corrosion of the metal or deterioration or sticking of the seal, and the packing will retain its flexibility. Provide reinforcing, filler rings, and separators if required to meet pressure and wear requirements. Maximum operating pressure is expected to be 1500 psig.

2.2.1.8 "O"-Rings

Existing O-Rings are made of ASTM D735-51T, Type S, Grade SC615 material.

Furnish and install new O-Rings made of material with equivalent or better mechanical properties and compatible with the hydraulic fluid used in the system.

2.2.1.9 Cylinder Studs

Existing cylinder studs are made of ASTM A320-52T, Grade L7 steel. Furnish and install new cylinder studs made of material with equivalent or better mechanical properties and quantity, dimensions, and threads to match existing for two cylinders, except threading the entire length of the stud is not required. Provide enough threads (approximately 2.5") at each end of the studs to allow nuts to be torqued as required.

2.2.1.10 Cylinder Stud Nuts

Existing cylinder stud nuts are made of ASTM A194-51, Grade 1 steel.

Furnish and install new cylinder stud nuts made of material with equivalent or better mechanical properties and quantity, dimensions, and threads to match existing for two cylinders.

2.2.1.11 Existing Piston

Pistons are made of cast iron meeting ASTM A48-48T, Class 40. Any weld rod used to make repairs to the piston must be compatible with this material.

The pistons in cylinders 1, 2, and 3 have 4 ring grooves. The pistons in cylinders 4, 5, and 6 have 6 ring grooves.

2.2.1.12 Piston Rings

Existing piston rings are "Koppers" bronze "step seal" hydraulic piston rings, 29" x 3/4". If new rings are required, furnish and install new rings that are equivalent to the existing rings in the quantities indicated.

2.2.1.13 Existing Piston Rod

Piston rods are made of corrosion resisting steel meeting Federal Specification QQ-S-763a-CL6, Type A (416 stainless steel). Any weld rod used to make repairs to the piston rod must be compatible with this material.

2.2.2 Hydraulic Fluid

The hydraulic fluid used in the cylinder hydraulic system is Chevron Clarity AW ISO 32. In order to maintain compatibility with the existing fluid, use Chevron Clarity AW ISO 32 during all testing and for filling the cylinders. No other fluid is acceptable.

2.2.3 Ball Valves

Furnish and install valves that are industry standard, commercially available, specifically designed and rated for hydraulic power system applications having published pressure ratings of at least 2,000 psig at 70°F. Valves must be full port design and have standard NPT ends(3/8" for bleed valves), 2 ports, zinc plated steel bodies, chrome-plated steel balls, MDS-filled Acetal plastic seats, and fluoroelastomer rubber seals.

Clearly and permanently mark OPEN and CLOSED positions on all valves.

Provide padlockable closed and open position locking device for lockout/tagout purposes on all valves.

2.2.4 Bonnet Cover Studs

Existing bonnet cover studs are made of C-1040 HR steel. Furnish and install new bonnet cover studs made of material with equivalent or better mechanical properties and quantity, dimensions, and threads to match existing for two slide gates. New studs required are parts 16 and 17 as shown on sheet FIO-029.

2.2.5 Bonnet Cover Stud Nuts

Existing bonnet cover stud nuts are made of ASTM A194 Class 2H forged steel. Furnish and install new bonnet cover stud nuts made of material with equivalent or better mechanical properties and quantity, dimensions, and threads to match existing for two slide gates.

2.2.6 Slide Gate Stem Nut Access Plate Cap Screws

Furnish and install new slide gate stem nut access plate cap screws, ASTM F879 alloy group 1, alloy condition CW, 80 ksi minimum tensile strength, 40 ksi minimum yield strength, flat head socket, 3/4 inch UNC, 1 inch long, quantity to match existing for two slide gates.

2.2.7 Bulkhead Slot Cover Plate Gasket

Furnish and install new bulkhead slot cover plate gaskets of quantity and dimensions to match existing for two slide gates. Use nylon fabric reinforced neoprene, 1/4 inch thick, 1,500 psi tensile strength, rated for outdoor use.

2.2.8 Hydraulic Piping

Design piping for a working pressure of at least 2,000 psig at 70°F and suitable for hydraulic power system applications. Furnish and install piping equal to or exceeding the requirements of ASME B31.1, and subsequent addenda unless otherwise specified or indicated herein.

2.2.8.1 Pipe

Use seamless steel conforming to ASTM A106/A106M, Grade B. Furnish and install carbon steel pipe in the pickled and oiled condition. Thread pipe as required for the application. Pipe shall conform to the cleanliness requirements of ISO 10763.

2.2.8.2 Pipe Fittings

Pipe fittings shall be threaded type conforming to ASME B16.11 and made of steel conforming to ASTM A234/A234M, Grade WPB.

2.3 SILVACEL PIPING

Furnish and install new Silvacel piping from components and materials as specified herein and as indicated on the Contract drawings. Submit shop drawings and product data. Include, as appropriate, catalog cuts, templates, types, grades and classes of materials and details of fabrication, assembly, and installation. Install new, government furnished valve (Part #4, M-401) in the new Silvacell piping as depicted.

2.3.1 Identification and Tagging

Each piece of pipe shall bear the ASTM designation and all other markings required for that designation.

2.3.2 Stainless Steel Pipe

Stainless steel pipe shall meet the requirements of ASTM A312/A312M, seamless, Grade TP304, TP304L, TP316, or TP316L, Schedule 10S with dimensions conforming to ASME B31.9.

2.3.3 Stainless Steel Grooved Fittings and Couplings

Grooved fittings shall be schedule 10S and rolled grooved from material conforming to ASTM A403/A403M Grade TP304, TP304L, TP316, or TP316L. Cut grooves will not be permitted. Couplings must have a housing fabricated in two or more parts of stainless steel castings conforming to ASTM A351/A351M and ASTM A743/A743M Grade CF-8M. Coupling gasket must be molded synthetic rubber, nitrile. Coupling bolts must be oval neck track head type conforming to ASTM F593, Group 2, type 316 stainless steel, condition CW, with hexagonal heavy nuts, conforming to ASTM F594, Group 2, Type 316 stainless steel, condition CW with galling resistant coating or type 316 stainless steel meeting the physical properties of ASTM A193/A193M ASTM A193/A193M, Grade B8M, Class 2.

2.4 Support Bolts

Support channels bolted to the bulkhead slot wall shall be fastened with bolts conforming to ASTM F593, Group 1, type 304 stainless steel.

2.5 SHOP PAINTING

Paint entire exterior surfaces of cylinders and all attached piping after completion of rehabilitation and assembly and prior to their return to the project site as specified in Section 09 97 02.02 28 PAINTING: HYDRAULIC

STRUCTURES (21-A-Z).

PART 3 EXECUTION

3.1 GENERAL

Exercise care so that fasteners are not overtightened to the extent that component bodies are distorted or damaged. Exercise extreme care during disassembly and reassembly to minimize spillage of hydraulic fluid and to avoid the entrance of abrasives, dirt, metal chips, and other foreign materials into the hydraulic system through open ends of piping and component ports. Under no circumstances are the cylinders to be operated by compressed air. Reinstall each cylinder on the slide gate from which it was removed. Follow manufacturer's installation instructions unless otherwise specified or indicated.

3.2 HYDRAULIC CYLINDER REMOVAL AND REINSTALLATION

3.2.1 Cylinder Removal

Submit a cylinder removal schedule at least 30 days in advance of the planned cylinder removal date. Include the planned cylinder removal date and dates for any other associated work at the outlet structure. The isolation bulkheads must be installed before the slide gates can be taken out of service and the cylinders removed. The outlet conduit must be drained in order to install the isolation bulkheads, and this takes the powerhouse out of service. Draining the outlet conduit and installation of the isolation bulkheads must be coordinated through the Contracting Officer's Representative. Once the isolation bulkheads are installed, the outlet conduit can be refilled, the powerhouse can be returned to service, and the cylinders can be removed. Leakage past the isolation bulkheads should be expected with the outlet conduit filled. The Government will perform all activities associated with draining the outlet conduit, but the Contractor must perform all other activities associated with the installation of the isolation bulkheads and removal of the cylinders.

3.2.2 Cylinder Installation

Submit a cylinder installation schedule at least 30 days in advance of the planned cylinder installation date. Include the planned cylinder installation date and dates for any other associated work at the outlet structure. Once the cylinders are reinstalled and field dry testing is complete, the outlet conduit can be drained, the isolation bulkheads can be removed, the outlet conduit can be refilled, and the powerhouse can be returned to service. The outlet conduit must be drained in order to remove the isolation bulkheads. Draining the outlet conduit and removal of the bulkheads must be coordinated through the Contracting Officer's Representative. The Government will perform all activities associated with draining the outlet conduit, but the Contractor must perform all other activities associated with the installation of the cylinders and the removal of the isolation bulkheads.

3.2.3 Cylinder Removal and Reinstallation Procedures

Remove and reinstall the hydraulic cylinders using the following handling procedures unless otherwise approved:

(1) Install the isolation bulkhead.

(a) The Government will drain the outlet conduit and authorize the Contractor to proceed.

(b) Open the slide gate.

(c) Remove the Silvacel piping. This is treated as a non-permit required confined space.

(d) Remove the bulkhead slot cover plate.

(e) Remove all Silvacel piping supports that are in the path of the isolation bulkhead. Measure and record location to facilitate installing the replacement.

(f) Remove remaining Silvacel piping supports. Measure and record location to facilitate installing the replacements

(g) Clean the bulkhead sealing surfaces.

(h) Install the isolation bulkhead.

(i) The Government will refill the outlet conduit.

(j) Reinstall the bulkhead slot cover plate and all fasteners hand tight to prevent debris and personnel from falling into the bulkhead slot and threaded holes.

(2) Place 3-12"X12" or 9-4"X4" cribbing timbers evenly spaced under the outlet slide gate leaf. Lower the outlet slide gate leaf to the bottom of its travel.

(3) Remove all the stud nuts that fasten the bonnet cover and cylinder to the slide gate bonnet. Do not disconnect hydraulic lines until later.

(4) Set the hydraulic system controls to extend the piston rod. This will lift the bonnet cover a fraction of an inch and crack the Permatex seal around the bonnet-cover joint.

(5) Remove the gate-position recorder selsyn connections. Take care to document connection details to ensure proper reconnection when cylinders are reinstalled.

(a) There are alarm sensors on the gate-position indicator that must be removed. Coordinate with the Contracting Officer's Representative so these sensors can be bypassed prior to their removal.

(b) Disconnect the selsyn motor electrical connections from the motor at the top of the cylinder.

(c) Disconnect the steel tape that operates the selsyn transmitter.

(d) Remove the electric conduits leading from the selsyn unit.

(6) Attach the crane hook to the cylinder with lifting sling through eye-bolts installed to replace two of the top head bolts.

(7) Disconnect the cylinder from the gate leaf.

(a) Remove the slide gate stem nut access plate from the downstream side of the gate leaf. Set access plate aside for later reinstallation.

(b) Remove the piston rod nut. It has a set screw that must be backed out first. Removal from the last half of the nut threads may require that the cylinder rod be retracted a few inches. Set rod nut aside for later reinstallation.

(8) Fully retract the piston rod into the cylinder.

(9) Close the isolation valve in the hydraulic line at the base of the cylinder.

(10) Disconnect the hydraulic lines from the cylinder. Catch hydraulic fluid that drains from the lines, and block both halves of all unions with gasketed plates. Leave the cylinder full of hydraulic fluid.

Leave attached to the cylinder the isolation valve at the bottom of the cylinder and the piping between this valve and the cylinder.

(11) Hoist the cylinder with the crane and position for transport to the repair facility.

(12) Install a temporary cover over the slide gate bonnet opening to prevent debris and personnel from falling into the bonnet opening and threaded holes.

(13) Perform cylinder reconditioning as outlined in paragraph HYDRAULIC

CYLINDER RECONDITIONING.

(14) Drain the hydraulic fluid reservoir, and if only one cylinder was reconditioned - the other cylinder serviced by the same hydraulic power unit shall be drained of used fluid. Dispose used hydraulic fluid in accordance with paragraph Disposal of Used Hydraulic Fluid. Refill hydraulic fluid reservoir and other cylinder if drained with the specified hydraulic fluid filtered to 10 microns, taking care to exclude all air. Clean the system of particles so that the contamination level is below 19/17/14 in accordance with ISO 4406.

(15) The reassembly procedure is substantially the reverse of the procedure for cylinder removal. Replace the bonnet cover studs and nuts and clean the contact surfaces between the bonnet and bonnet cover and apply sealant when reinstalling the bonnet cover. Observe thread classifications on studs, nuts, and tapped holes to ensure proper stud installation.

(16) After reconnecting the hydraulic lines, air may be removed from the system by opening the air bleed valves at the top and bottom of the cylinder. Some air may be trapped under the piston, but this will work up past the piston during operation. Replace the slide gate stem nut access plate cap screws and clean the contact surfaces between the gate leaf and access plate and apply sealant when reinstalling the stem nut access plate.

(17) Perform dry tests as outlined in paragraph DRY TESTS.

(18) Remove the isolation bulkhead.

(a) The Government will drain the outlet conduit and authorize the Contractor to proceed.

(b) Open the slide gate.

(c) Remove the bulkhead slot cover plate.

(d) Remove the isolation bulkhead.

(e) Clean the bulkhead slot cover plate sealing surfaces.

(f) Cement the new bulkhead slot cover plate gasket to the cover plate.

(g) Reinstall the bulkhead slot cover plate.

(h) Install the new Silvacel piping and supports as indicated on the Contract drawings.

(i) Close the slide gate.

(j) The Government will refill the outlet conduit.

(k) Observe the cover plate for leakage. Any leakage around the cover plate is unacceptable. If there is leakage, the Government will drain the outlet conduit, allow the Contractor to reseal the cover plate, and refill the outlet conduit. The Contractor is responsible for ensuring there is no leakage around the bulkhead slot cover plate.

(l) Some leakage around the slide gate is expected, but the Contractor is not responsible to correct this leakage.

(19) Perform wet tests as outlined in paragraph WET TESTS.

3.3 HYDRAULIC CYLINDER RECONDITIONING

3.3.1 General

After removing the cylinders from the slide gates, ship the cylinders to the repair facility for inspection and repair. Upon arrival at the repair facility drain the hydraulic fluid, dispose of in accordance with paragraph Disposal of Used Hydraulic Fluid and perform Initial Hydrostatic Tests as outlined in paragraph SHOP TESTS. Prior to disassembly of the cylinders, blast clean all external surfaces of each cylinder, including bonnet cover and cylinder head, to remove paint for inspection, and match mark parts.

Exercise care to ensure machine finished surfaces are not damaged during blasting. Upon disassembly, the Contractor and Contracting Officer's Representative will inspect the cylinder components to determine the extent of repairs the Contractor is to perform. Perform non-destructive testing as outlined in Section 05 05 33.10 26 NON-DESTRUCTIVE TESTING. All repair/rebuild procedures must be approved by the Government before commencing any repair/rebuild work. Upon completion of repairs and reassembly, and prior to returning the cylinders, perform Final Hydrostatic Tests as outlined in paragraph SHOP TESTS.

3.3.2 Disposal of Used Hydraulic Fluid

As received, the hydraulic fluid in the cylinders may be contaminated and must be removed at the repair facility prior to Initial Hydrostatic Tests.

Used hydraulic fluid must be disposed in accordance with Section

01 57 20.00 28 ENVIRONMENTAL PROTECTION.

3.3.3 Cylinder Exterior

After removal of paint from the cylinder exterior surfaces and disassembly, examine the exterior of the cylinder shells. Repair pits or other defects deeper than 1/8 inch using an approved welding procedure. Record all observations of initial and final conditions and submit as part of the Final Hydrostatic Test Report.

3.3.4 Packings, Seals, and Fasteners

Replace all cylinder packings, seals, studs, and nuts. Furnish replacement parts that are identical to OEM items in the cylinders or an approved equal to the original item, except cylinder studs may be supplied with threaded ends only instead of being all-thread.

3.3.5 Cylinder Interior

Check cylinder shells for straightness using boring mill, and dial indicate longitudinal inside diameter on 12 inch centers. Measure shell inside diameter on 12 inch centers in eight divisions. Dial indicate flanges and bores to check concentricity and perpendicularity as applicable. After inspection and measurement, the Contractor and Contracting Officer's Representative will determine if repairs are required. If required, hone the cylinder shell interior to return it to OEM finish conditions or better. If repair in addition to honing is required, such as corrosion pitting repair, the Contractor and Contracting Officer's Representative will determine the amount of additional repair to be performed. If required, repair pits or other defects using an approved welding procedure and refinish to meet OEM finish conditions or better. Maximum honing allowed on the cylinder shell inside diameter is 0.010 inch. See paragraph CYLINDER DEFECT REPAIR, below, for information on additional repairs.

After repairs are completed, clean all debris from the cylinder shells.

Record all observations and measurements of initial and final conditions and submit as part of the Final Hydrostatic Test Report.

3.3.6 Piston Rod

Removal of the piston from the rod is not necessary unless required to perform repairs. Check rods for straightness by chucking them in a lathe and dial indicate longitudinal diameter on 12 inch centers. Measure rod diameter on 12 inch centers in eight divisions. After inspection and measurement, the Contractor and Contracting Officer's Representative will determine if repairs are required. Repair and refinish the surface of the rod if it is unsatisfactory. Weld-repair pits or scratches in the rod using 416 stainless steel rod and an approved welding procedure prior to refinishing. Finish the repaired area to meet OEM finish conditions or better. See paragraph CYLINDER DEFECT REPAIR, below, for information on additional repairs. Clean the rods of all debris after repairs are completed. Record all observations and measurements of initial and final conditions and submit as part of the Final Hydrostatic Test Report.

3.3.7 Piston and Piston Rings

Clean, examine, and measure the pistons and piston rings for wear and other damage. After inspection and measurement, the Contractor and Contracting Officer's Representative will determine if repairs are required and if the rings can be reused. Repair and refinish piston surfaces using an approved procedure if they are unsatisfactory. Finish the repaired areas to meet OEM finish conditions or better. See paragraph CYLINDER DEFECT REPAIR, below, for information on additional repairs. If new rings are needed, furnish and install new rings of material and size to duplicate OEM conditions. If the old rings can be resized and reused, perform all required operations for resizing to duplicate OEM conditions. If the existing piston rings are removed and then reinstalled, or if new rings are installed, install them with the pressure side as shown and with the ring end gaps offset from each other in accordance with standard industry practice. After repairs are completed, clean all debris from the piston and rings. Record all observations and measurements of initial and final conditions and submit as part of the Final Hydrostatic Test Report.

3.3.8 Cylinder Head

Clean, examine, and check flange and bores for concentricity, flatness, and perpendicularity as applicable. After inspection and measurement, the Contractor and Contracting Officer's Representative will determine if repairs are required. Repair and refinish cylinder head surfaces using an approved procedure if they are unsatisfactory. Finish the repaired areas to meet OEM finish conditions or better. See paragraph CYLINDER DEFECT REPAIR, below, for information on additional repairs. After repairs are completed, clean all debris from the cylinder head. Record all observations and measurements of initial and final conditions and submit as part of the Final Hydrostatic Test Report.

3.3.9 Bonnet Cover and Glands

Clean, examine, and check flanges and bores for concentricity, flatness, parallelism, and perpendicularity as applicable. Measure gland clearances between piston rod and bonnet cover. After inspection and measurement, the Contractor and Contracting Officer's Representative will determine if repairs are required. Repair and refinish bonnet cover surfaces using an

SECTION 41 24 27.10 28

approved procedure if they are unsatisfactory. Finish the repaired areas to meet OEM finish conditions or better. See paragraph BONNET COVER REPAIR, below, for information on additional repairs. If new glands are needed, furnish and install new glands of material and size to duplicate OEM conditions. If the old glands can be resized and reused, perform all required operations for resizing to duplicate OEM conditions. Clean all debris from the bonnet cover and glands after repairs are completed.

Record all observations and measurements of initial and final conditions and submit as part of the Final Hydrostatic Test Report.

3.3.10 Reassembly

Before reassembly, thoroughly clean all hydraulic cylinder components of all contamination. Reassemble each cylinder with new seals, packings, fasteners, and other parts as specified. Exercise extreme care during shop assembly to avoid inclusion of foreign materials into the cylinders.

Replace the bleed piping and valves on the bonnet covers. Furnish and install a section of pipe between the bonnet cover and the ball valve of adequate, but not excessive, length to provide clearance for the ball valve and its handle. Fill with the specified hydraulic fluid filtered to 10 microns, taking care to exclude all air. Clean the system of particles so that the contamination level is below 19/17/14 in accordance with ISO 4406.

3.4 CYLINDER INTERIOR DEFECT REPAIR

a. Cylinder Defect Repair includes repairs identified and agreed upon during the inspections of the Cylinder, and related items, as identified above. During the inspections, the extent of repair on specified items shall be determined, agreed upon between the Contractor and the Government, and documented in writing, prior to the Contractor starting work on the related repairs. Only work identified during these inspections will approved for payment. Costs for repairs in these areas will be paid for separately on a unit priced basis as described in SECTION 01 22 00.00 28 MEASUREMENT AND PAYMENT, paragraph CLIN 0005 CYLINDER DEFECT REPAIR. Work included with repairs includes the following:

1. Welding.

2. Remachining of repaired areas.Honing repair areas.

3. Refinishing of repaired areasHoning repair areas. Assume each cylinder interior requires honing.

4. Supervision, equipment, tools, labor, materials, overhead, transportation, travel, and incidentals required.

b. Estimated Quantity (square inches) of CYLINDER DEFECT REPAIR is based on an average weld depth of 1/8".

3.5 BONNET COVER REPAIR

a. Bonnet Cover Repair includes repairs identified and agreed upon during the inspections of the Bonnet Cover and Glands, as identified above. During the inspections, the extent of repair on the Bonnet Covers shall be determined, agreed upon between the Contractor and the Government, and documented in writing, prior to the Contractor starting work on the related repairs. Only work identified during these inspections will approved for payment. Costs for repairs in these

SECTION 41 24 27.10 28

areas will be paid for separately on a unit priced basis as described in SECTION 01 22 00.00 28 MEASUREMENT AND PAYMENT, paragraph CLIN 0006 BONNET COVER REPAIR. Work included with repairs includes the following:

1. Welding.

2. Honing repair areas.Remachining of repaired areas.

3. Refinishing of repaired areas.Honing repair areas.

4. Supervision, equipment, tools, labor, materials, overhead, transportation, travel, and incidentals required.

b. Estimated Quantity (square inches) of BONNET COVER REPAIR is based on an average finished build-up thickness of 0.010".

3.6 SHOP TESTS

Pressure test each cylinder to assure they meet the specified operating requirements. Perform tests in the presence of the Contracting Officer's Representative unless otherwise authorized in writing. Provide rod support to limit rod flexing and bonnet cover gland side-loading while stroking the cylinders. Perform tests using hydraulic fluid that is at least 70°F.

3.6.1 Initial Hydrostatic Tests

Perform shop tests of each cylinder before performing any disassembly or reconditioning. Fill the system with the specified hydraulic fluid filtered to 10 microns, taking care to exclude all air. Hydrostatically test each cylinder at 1,500 psig for a minimum of 1 hour in each direction. With the rod retracted, and the pressure applied to the rod side of the piston, crack open the vent valve on the top of the cylinder, observe and record any leakage past the piston, cylinder seals, and rod packing. Close the vent valve prior to going to the next step. With the rod extended, and the pressure applied to the top side of the piston, crack open a valve on the bottom of the cylinder, observe and record any leakage past the piston, cylinder seals, and rod packing. Submit Initial Hydrostatic Test Schedules and Initial Hydrostatic Test Reports.

3.6.2 Final Hydrostatic Tests

Perform shop tests of each cylinder after completing all reconditioning and reassembly. Fill the system with the specified hydraulic fluid, new from manufacturer sealed containers and filtered to 10 microns, taking care to exclude all air. Clean the system of particles so that the contamination level is below 19/17/14 in accordance with ISO 4406. Hydrostatically test each cylinder at 1,500 psig for a minimum of 1 hour in each direction.

With the rod retracted, and the pressure applied to the rod side of the piston, observe and record any leakage past the piston, cylinder seals, and rod packing. With the rod extended, and the pressure applied to the top side of the piston, observe and record any leakage past the piston, cylinder seals, and rod packing. Any leakage past the cylinder seals or rod packing under either condition will be cause for rejection. Leakage under either condition in excess of that recorded in the initial tests or two gallons per hour, whichever is lower, past the piston will be cause for rejection. In the case that a cylinder does not pass the shop test, perform such additional work as approved or directed to assure that the cylinder will pass the test. Retest the cylinder as necessary to assure that it meets the test requirements. Fully retract the piston rod into the

SECTION 41 24 27.10 28

cylinder after testing. Submit Final Hydrostatic Test Schedules and Final Hydrostatic Test Reports.

3.7 FIELD TESTS AND INSPECTIONS

Provide all fluid, instruments, and personnel required for the field tests. Conduct testing in the presence of the Contracting Officer's Representative, unless waived in writing. Correct any cylinder deficiencies disclosed by the tests immediately and repeat the test until satisfactory results are obtained. Conduct all field tests during the project work hours as outlined in Section 01 11 01.00 28 SUPPLEMENTARY REQUIREMENTS. Submit Field Test Schedules, and Field Test Reports.

3.7.1 Filling and Bleeding the System

Filter the specified fluid used to fill the system through a 10 micron filter. Fill the hydraulic cylinder and the piping in a manner that excludes as much air as possible. Ensure that the hydraulic reservoir fluid is at the proper level.

3.7.2 Final Acceptance Tests

3.7.2.1 Dry Test

After completion of reassembly and reinstallation of the cylinders on the slide gates and appurtenant components, and prior to removal of the isolation bulkheads, operate each gate through one complete cycle to demonstrate that no leaks exist in the hydraulic system and that the gate system is fully operational. Coordinate with COR and Lucky Peak Power Plant to run the hydraulic power unit when restarting. Read and record the pressure in the supply and return lines for each direction of operation.

Record pertinent observations regarding such events as unusual sounds, malfunctions or difficulties encountered, and adjustments required.

3.7.2.2 Wet Test

After removal of the isolation bulkheads and the outlet conduit has been refilled, operate each gate through one partial cycle (1 to 4 feet open) to demonstrate that no leaks exist in the hydraulic system and that the gate system is fully operational. Read and record the pressure in the supply and return lines for each direction of operation. Record pertinent observations regarding such events as unusual sounds, malfunctions or difficulties encountered, and adjustments required.

3.8 FIELD TOUCH UP PAINTING

After reinstallation of the cylinders, repair chips, scratches, and other damage to shop-applied painted surfaces in the field to match the original finish as specified in section 09 97 02.02 28 PAINTING: HYDRAULIC

STRUCTURES (21-A-Z).

-- End of Section --

1.8 WARRANTY

3.8 FIELD TOUCH UP PAINTING