TECHSPECS_25RA010_LLA Hyd Sys_amd0009.pdf

Lower Granite Turbine Intake Gate Hydraulic System Upgrade W912EF25RA010 amd 0009

PROJECT TABLE OF CONTENTS

DIVISION 01 - GENERAL REQUIREMENTS

01 00 00.00 28 GENERAL REQUIREMENTS

01 11 00.00 28 SUMMARY OF WORK

01 11 01.00 28 SUPPLEMENTARY REQUIREMENTS

01 12 16.00 26 WORK SEQUENCE

01 14 00.10 28 PROJECT SITE RESTRICTIONS

01 14 00.90 28 INTEGRATING ANTITERRORISM (AT) AND OPERATIONS SECURITY

(OPSEC)

01 20 00.00 20 PRICE AND PAYMENT PROCEDURES

01 22 00.00 28 MEASUREMENT AND PAYMENT

01 32 01.00 28 PROJECT SCHEDULE

01 33 00 SUBMITTAL PROCEDURES

01 35 29.10 28 GOVERNMENTAL SAFETY REQUIREMENTS

01 42 00 SOURCES FOR REFERENCE PUBLICATIONS

01 45 01.00 28 RESIDENT MANAGEMENT SYSTEM CONTRACTOR MODE (RMS CM)

01 45 04.00 28 CONTRACTOR QUALITY CONTROL

01 51 00.00 28 TEMPORARY UTILITIES

01 55 10.00 28 CONTRACTOR WORK, ACCESS AND STORAGE AREAS

01 57 20.00 28 ENVIRONMENTAL PROTECTION

01 78 00.00 28 CLOSEOUT SUBMITTALS

01 78 23.00 28 OPERATION AND MAINTENANCE DATA

01 79 00.00 28 DEMONSTRATION AND TRAINING

01 91 00.00 26 SYSTEMS TESTING AND COMMISSIONING

DIVISION 02 - EXISTING CONDITIONS

02 82 13.01 28 CLASS II ASBESTOS ABATEMENT

02 83 33.14 28 REMOVAL/CONTROL AND DISPOSAL OF PAINT WITH LEAD - SHORT

VERSION

DIVISION 03 - CONCRETE

03 45 33.00 28 PRECAST STRUCTURAL CONCRETE

03 60 00.01 26 CONCRETE DEMOLITION, REPAIR OF CONCRETE SURFACES, AND

MINOR EQUIPMENT FOUNDATIONS

DIVISION 05 - METALS

05 05 23.17 26 WELDING (STEEL), FABRICATION, AND MACHINE WORK

05 50 04.00 26 METALS: MATERIALS, PRODUCTS, AND MISCELLANEOUS ITEMS

DIVISION 07 - THERMAL AND MOISTURE PROTECTION

07 84 00.00 28 FIRESTOPPING

07 92 00.00 28 JOINT SEALANTS

DIVISION 09 - FINISHES

09 97 02.13 26 PAINTING - STEEL STRUCTURES

DIVISION 13 - SPECIAL CONSTRUCTION

13 48 00.00 26 SEISMIC RESTRAINT FOR MECHANICAL AND ELECTRICAL EQUIPMENT

DIVISION 25 - INTEGRATED AUTOMATION

PROJECT TABLE OF CONTENTS Page 1

25 05 11.01 26 CYBERSECURITY FOR CONTROL SYSTEMS

DIVISION 26 - ELECTRICAL

26 05 00.00 26 BASIC ELECTRICAL MATERIALS AND METHODS

26 05 19.00 26 INSULATED WIRE AND CABLE

26 05 26.00 26 GROUNDING

26 05 36.00 26 CABLE TRAYS FOR ELECTRICAL SYSTEMS

26 42 14.01 26 CATHODIC PROTECTION BY SACRIFICIAL ANODES

DIVISION 27 - COMMUNICATIONS

27 21 10.00 26 FIBER OPTIC DATA TRANSMISSION SYSTEM

DIVISION 33 - UTILITIES

33 56 53.00 26 HYDRAULIC FLUID STORAGE TANK

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

35 05 40.14 26 HYDRAULIC POWER SYSTEMS FOR CIVIL WORKS STRUCTURES

35 05 40.15 26 HYDRAULIC FLUID

DIVISION 40 - PROCESS INTERCONNECTIONS

40 05 13.96 26 WELDING: PIPING AND PRESSURIZED SYSTEMS

40 95 13.00 26 PROCESS CONTROL PANELS AND HARDWARE

40 95 23.00 26 PROGRAMMABLE LOGIC CONTROLLER HARDWARE

DIVISION 41 - MATERIAL PROCESSING AND HANDLING EQUIPMENT

41 22 13.75 26 NEW SUPPORT BEAMS AND LIFTING DEVICES

-- End of Project Table of Contents --

PROJECT TABLE OF CONTENTS Page 2

SECTION TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

SECTION 35 05 40.14 26

HYDRAULIC POWER SYSTEMS FOR CIVIL WORKS STRUCTURES

PART 1 GENERAL

1.1 SUMMARY

1.2 REFERENCES

1.3 SUBMITTALS

1.4 DESIGN AND PERFORMANCE REQUIREMENTS

1.4.1 Definitions

1.4.2 System Summary

1.4.3 Design Parameters

1.4.4 Allowable Stresses

1.4.4.1 Load Cases and Allowable Stresses

1.4.4.2 Stress Concentration Factors

1.4.5 Corrosivity Environment Category

1.4.6 Connections

1.4.6.1 Pinned Connections

1.4.6.2 Shop Connections

1.4.6.3 Welded Connections

1.5 QUALITY ASSURANCE

1.5.1 Hydraulic System Designer Qualifications

1.5.2 Submittal Packages

1.5.2.1 Submittal Package General Requirements

1.5.2.2 Submittal Package Contents

1.5.2.3 Initial Conference

1.5.3 Drawings

1.5.3.1 General Drawing Requirements

1.5.3.2 Fabrication Drawings

1.5.3.3 Hydraulic Cylinder Drawings

1.5.3.4 Hydraulic Power Unit Drawings

1.5.3.5 Piping Drawings

1.5.3.6 Control Drawings

1.5.3.7 Hydraulic Schematic

1.5.3.8 Electrical Drawings

1.5.3.9 3D Computer Model

1.5.4 Product Data

1.5.5 Calculations

1.5.5.1 Calculation Requirements

1.5.5.2 Calculation Packages

1.6 COMPONENT AND FLUID COMPATIBILITY

1.6.1 General Compatibility Requirements

1.6.2 Manufacturer's Published Ratings

1.6.3 Compatibility Testing

1.7 QUALITY CONTROL

PART 2 PRODUCTS

2.1 MATERIALS AND MECHANICAL EQUIPMENT

SECTION 35 05 40.14 26 Page 1

2.1.1 General

2.1.2 Standard Products

2.2 HYDRAULIC FLUID

2.3 HYDRAULIC CYLINDERS

2.3.1 General Design and Configuration

2.3.2 End Configurations

2.3.2.1 Rod End

2.3.2.2 Cylinder End

2.3.2.3 Cylinder Support

2.3.3 Cylinders

2.3.4 Piston Rods

2.3.4.1 Piston Rod General Requirements

2.3.4.2 Piston Rod Coating Data

2.3.5 Pistons

2.3.6 Seals, O-Rings And Bearing Materials

2.3.6.1 Serviceability

2.3.6.2 Material Compatibility

2.3.6.3 Temperature Ranges

2.3.6.4 Piston Wear Rings

2.3.6.5 Piston Seal Rings

2.3.6.6 O-Ring Seals

2.3.6.7 Rod Wiper/Scraper

2.3.6.8 Piston Rod Seals

2.3.7 Rod Seal Gland

2.3.8 Anodes

2.4 HOIST POSITION TRANSDUCER

2.5 HOIST LOCKING DEVICE

2.5.1 Hoist Locking Device General Requirements

2.5.2 Hoist Locking Device Load Cases and Allowable Stresses

2.5.3 Hoist Locking Device Materials

2.6 CYLINDER HANDLING DEVICE

2.7 STUB PISTON RODS AND COUPLINGS

2.7.1 Stub Piston Rods and Coupling General Requirements

2.7.2 Stub Piston Rods and Couplings Quantity

2.7.3 Stub Piston Rods and Couplings Materials

2.7.4 Stub Piston Rods and Couplings Load Cases and Allowable

Stresses

2.8 HYDRAULIC POWER UNIT (HPU)

2.8.1 HPU Arrangement

2.8.2 General - HPU

2.8.3 Gauges

2.8.4 Control Equipment

2.8.5 Pumps

2.8.6 Pump Motors

2.8.7 Manifold Block

2.8.8 Low-Pressure Return Filters/Strainers

2.8.9 High-Pressure Discharge Filters

2.8.10 Skid

2.8.11 Connection to Headers

2.9 CONTROL STATION

2.9.1 General

2.9.2 Manifold Block

2.9.3 Valves

2.9.4 Gauges

2.9.5 Control Panel

2.10 ACCUMULATOR TANKS

2.11 MANIFOLD BLOCKS

2.12 PIPING

2.12.1 General - Piping

SECTION 35 05 40.14 26 Page 2

2.12.2 Pipe Sizing

2.12.3 Pipe

2.12.4 Pipe Fittings

2.12.5 Unions and Assembly Joints

2.12.6 Expansion Fittings

2.13 TUBING

2.13.1 Use of Tubing

2.13.2 Tube

2.13.3 Tube Fittings

2.14 VALVES

2.14.1 General - Valves

2.14.2 In-line Shutoff Valves

2.14.3 Manifold Mounted Shutoff Valves

2.14.4 Spring Loaded Check Valves

2.14.5 Swing Check Valves

2.14.6 Pressure Compensated Flow Control Valves

2.14.7 Screw-In Cartridge Valves

2.14.8 Slip-In Cartridge Valves

2.14.9 Directional Control Valves (Solenoid Operated)

2.14.10 Pressure Relief Valves

2.14.11 Unloading Valves

2.14.12 Bleeder Valves

2.15 INSTRUMENTS AND APPURTENANCES

2.15.1 Pressure Switches

2.15.2 Pressure Snubbers

2.15.3 Pressure Gauges

2.16 FLEXIBLE HOSES

2.16.1 General

2.16.2 Flexible Hose

2.16.3 Flexible Hose Fittings

2.17 PIPE AND TUBING SUPPORTS

2.18 FASTENERS

2.19 NAMEPLATES

2.20 ELECTRICAL EQUIPMENT

2.21 SPECIAL TOOLS

2.22 SPARE PARTS

PART 3 EXECUTION

3.1 EXAMINATION

3.2 FABRICATION

3.2.1 Welding

3.2.2 Metal Work

3.2.3 Painting

3.2.4 Hydraulic Cylinders

3.2.4.1 Cylinder Manufacturers QC Procedures

3.2.4.2 Dimensions to Verify

3.2.4.3 Dimensional Verification Procedure

3.2.4.4 Dimensional Verification Report

3.3 SHOP ASSEMBLY AND TESTING

3.3.1 Shop Assembly

3.3.2 Protection During Assembly

3.3.3 Cleaning and Protection During Assembly

3.3.4 Flushing

3.3.5 Shop Testing

3.3.5.1 General - Shop Testing

3.3.5.2 Notification of Shop Testing

3.3.5.3 Cylinder Tests

3.3.5.4 Hydraulic Power Unit Tests

SECTION 35 05 40.14 26 Page 3

3.3.5.5 Control Station Tests

3.3.5.6 Draining of Fluid

3.3.5.7 Shop Testing Plan

3.3.5.8 Shop Testing Report

3.4 SHIPPING, DELIVERY, STORAGE, AND HANDLING

3.4.1 Preparation for shipping

3.4.2 Packaging

3.4.3 Packaging Requirements for Hydraulic Cylinders

3.4.4 Shipping and Storage On-Site

3.4.5 Cylinders Designated for Long Term Storage

3.5 ON-SITE REMOVAL AND INSTALLATION

3.5.1 Sequence Of Work

3.5.2 Removal Procedures

3.5.3 Installation Procedures

3.5.4 Removal Of Existing Equipment

3.5.4.1 Repair of Surfaces

3.5.4.2 Existing Hydraulic Fluid

3.5.4.3 Existing Hydraulic Fluid Storage Tank

3.5.4.4 Existing HPU

3.5.4.5 Existing Distribution Headers

3.5.4.6 Existing Hydraulic Fluid Storage Tank Piping

3.5.4.7 Existing Hydraulic Cylinders

3.5.4.8 Existing Hydraulic Hoses

3.5.4.9 Existing Control Stations

3.5.4.10 Gate Position Indicators

3.5.5 Installation of New Equipment

3.5.5.1 HPU

3.5.5.2 Distribution Header Piping

3.5.5.3 Hydraulic Cylinders

3.5.5.4 Flexible Hoses

3.5.5.5 Control Stations

3.6 IDENTIFICATION OF PIPING AND VALVES

3.7 CLEANING AND FLUSHING

3.7.1 Cleaning and Flushing Procedures and Results

3.7.2 Flushing Piping and Tubing

3.7.3 Flushing Manifolds and Hoses

3.7.4 System Cleanliness

3.8 FILLING AND BLEEDING THE SYSTEM

3.9 ERECTION ENGINEER

3.10 ON-SITE TESTING AND INSPECTION

3.10.1 On-Site Testing General Requirements.

3.10.1.1 Government Witness

3.10.1.2 Unit Watering Status for Testing

3.10.2 Hydraulic Cylinder Dry Pressure and Operational Testing

3.10.2.1 Hydraulic Cylinder Testing Requirements

3.10.2.2 Hydraulic Cylinder Testing Plan

3.10.2.3 Hydraulic Cylinder Testing Report

3.10.3 Pressure Testing

3.10.3.1 Pressure Testing Requirements

3.10.3.2 Pressure Testing Plan

3.10.3.3 Pressure Testing Report

3.10.4 Functional Testing

3.10.4.1 General - Functional Testing

3.10.4.2 HPU Functional Testing

3.10.4.3 Control Station and Gate Functional Testing

3.10.4.4 Functional Testing Plan

3.10.4.5 Functional Test Report

3.10.5 Operational Testing

3.10.5.1 General - Operational Testing

SECTION 35 05 40.14 26 Page 4

3.10.5.2 Hydraulic System Operational Testing

3.10.5.3 Operational Testing Plan

3.10.5.4 Operational Testing Report

3.11 CLEAN-UP

3.12 TRAINING

3.12.1 Training Requirements

3.12.2 Training Instructor

3.12.3 Recording of Training Sessions

3.13 OPERATION AND MAINTENANCE

-- End of Section Table of Contents --

SECTION 35 05 40.14 26 Page 5

THIS PAGE INTENTIONALLY LEFT BLANK

SECTION 35 05 40.14 26 Page 6

SECTION 35 05 40.14 26

HYDRAULIC POWER SYSTEMS FOR CIVIL WORKS STRUCTURES

PART 1 GENERAL

1.1 SUMMARY

The work covered by this section consists of detailed requirements for the design, fabrication, shop assembly, testing, delivery, and installation of the new hydraulic power system, including new cylinders, for operation of the intake gates.

1.2 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME A13.1 (2023) Scheme for the Identification of Piping Systems

ASME B1.20.1 (2013; R 2018) Pipe Threads, General Purpose (Inch)

ASME B16.5 (2020) Pipe Flanges and Flanged Fittings NPS 1/2 Through NPS 24 Metric/Inch Standard

AMERICAN WATER WORKS ASSOCIATION (AWWA)

AWWA C508 (2017) Swing-Check Valves for Waterworks Service, 2 In. Through 48-In. (50-mm Through 1,200-mm) NPS

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2020; Errata 1 2021) Structural Welding Code - Steel

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B16.11 (2022) Forged Fittings, Socket-Welding and Threaded

ASME B30.20 (2018) Below-the-Hook Lifting Devices

ASME B31.1 (2022) Power Piping

ASME B36.19M (2022) Welded and Seamless Wrought Stainless Steel Pipe

ASME B40.100 (2013) Pressure Gauges and Gauge Attachments

SECTION 35 05 40.14 26 Page 7

ASME BPVC (2010) Boiler and Pressure Vessels Code

ASME BPVC SEC IX (2017; Errata 2018) BPVC Section IX-Welding, Brazing and Fusing Qualifications

ASME BTH-1 (2014) Design of Below-the-Hook Lifting Devices

ASTM INTERNATIONAL (ASTM)

ASTM A36/A36M (2019) Standard Specification for Carbon Structural Steel

ASTM A105/A105M (2021) Standard Specification for Carbon Steel Forgings for Piping Applications

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

ASTM A108 (2013) Standard Specification for Steel Bar, Carbon and Alloy, Cold-Finished

ASTM A182/A182M (2022) Standard Specification for Forged or Rolled Alloy and Stainless Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service

ASTM A193/A193M (2023) Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service and Other Special Purpose Applications

ASTM A194/A194M (2023) Standard Specification for Carbon Steel, Alloy Steel, and Stainless Steel Nuts for Bolts for High-Pressure or High-Temperature Service, or Both

ASTM A216/A216M (2021) Standard Specification for Steel Castings, Carbon, Suitable for Fusion Welding, for High-Temperature Service

ASTM A217/A217M (2022) Standard Specification for Steel Castings, Martensitic Stainless and Alloy, for Pressure-Containing Parts, Suitable for High-Temperature Service

ASTM A234/A234M (2022) Standard Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and High Temperature Service

ASTM A240/A240M (2023a) Standard Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications

ASTM A266/A266M (2021) Standard Specification for Carbon

SECTION 35 05 40.14 26 Page 8

Steel Forgings for Pressure Vessel Components

ASTM A269/A269M (2015; R 2019) Standard Specification for Seamless and Welded Austenitic Stainless Steel Tubing for General Service

ASTM A312/A312M (2021) Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes

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

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

ASTM A572/A572M (2021; E 2021) Standard Specification for High-Strength Low-Alloy Columbium-Vanadium Structural Steel

ASTM B209 (2014) Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate

ASTM B505/B505M (2022) Standard Specification for Copper Alloy Continuous Castings

ASTM B733 (2022) Standard Specification For Autocatalytic (Electroless) Nickel-Phosphorus Coatings On Metal

ASTM D7647 (2010; R 2018) Standard Test Method for Automatic Particle Counting of Lubricating and Hydraulic Fluids Using Dilution Techniques to Eliminate the Contribution of Water and Interfering Soft Particles by Light Extinction

ASTM G48 (2011; R 2015) Standard Test Methods for Pitting and Crevice Corrosion Resistance of Stainless Steels and Related Alloys by Use of Ferric Chloride Solution

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 1219-1 (2012; Amd 1 2016) Fluid Power Systems and Components Graphic Symbols and Circuit Diagrams - Part 1: Graphic Symbols for Conventional Use and Data-Processing Applications

ISO 1219-2 (2012) Fluid Power Systems and Components Graphic Symbols and Circuit Diagrams - Part 2: Circuit Diagrams

ISO 1817 (2015) Rubber, Vulcanized or Thermoplastic

- Determination of the Effect of Liquids - Sixth Edition

SECTION 35 05 40.14 26 Page 9

ISO 4287 (1997, Amd 1 2009)Geometrical Product Specifications (GPS) - Surface Texture:

Profile Method - Terms, Definitions and Surface Texture Parameters - First Edition

ISO 4288 (1996, Corr 1 1998)Geometrical Product Specifications (GPS) - Surface Texture:

Profile Method - Rules and Procedures for the Assessment of Surface Texture - Second Edition

ISO 4401 (2005) Hydraulic Fluid Power - Four-port Directional Control Valves - Mounting Surfaces

ISO 4406 (2021) Hydraulic Fluid Power - Fluids - Method for Coding the Level of Contamination by Solid Particles

ISO 4413 (2010) Hydraulic Fluid Power — General Rules and Safety Requirements for Systems and Their Components

ISO 5817 (2014) Welding - Fusion-Welded Joints in Steel, Nickel, Titanium And Their Alloys (Beam Welding Excluded) - Quality Levels For Imperfections - Third Edition

ISO 6507 (2018) Metallic Materials -- Vickers Hardness Test -- Part 1: Test Method - Fourth Edition

ISO 7368 (2016) Hydraulic Fluid Power - Two-port slip-in cartridge valves - Cavities

ISO 7789 (2007) Hydraulic Fluid Power - Two-, Three-, and Four-port Screw-In Cartridge Valves - Cavities

ISO 9001 (2015) Quality Management Systems- Requirements

ISO 9223 (2012) Corrosion of Metals and Alloys — Corrosivity of Atmospheres — Classification, Determination and Estimation - Second Edition

ISO 15614-7 (2016) Specification and Qualification of Welding Procedures for Metallic Materials

- Welding Procedure Test - Part 7: Overlay Welding - Second Edition

MANUFACTURERS STANDARDIZATION SOCIETY OF THE VALVE AND FITTINGS

INDUSTRY (MSS)

MSS SP-58 (2018) Pipe Hangers and Supports - Materials, Design and Manufacture, Selection, Application, and Installation

SECTION 35 05 40.14 26 Page 10

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA MG 1 (2021) Motors and Generators

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

SAE J514 (2012) Hydraulic Tube Fittings

SAE J517 (2020) Hydraulic Hose

SAE J518-1 (2013) Hydraulic Flanged Tube, Pipe, and Hose Connections, 4-Screw Flange Connection Part 1: 3.5 MPa to 35 MPa (Code 61)

SAE J1273 (2020) Recommended Practices for Hydraulic Hose Assemblies.

1.3 SUBMITTALS

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

submittals having an "I" designation are for information only. 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

Notification Of Shop Testing ; I HDC

Shop Testing Plan ; G, HDC

Pressure Testing Plan ; G, HDC

Functional Testing Plan ; G, HDC

Hydraulic Cylinder Packaging Plan ; I, HDC

Cylinders Designated For Long Term Storage ; I, HDC

Hydraulic Cylinder Shop Testing Plan ; G, HDC

Hydraulic Power Unit Shop Testing Plan ; G, HDC

Control Station Shop Testing Plan ; G, HDC

Installation Procedures ; G, HDC

Removal Procedures ; G, HDC

Dimensional Verification Procedure ; G, HDC

Cylinder Manufacturers Qc Procedures ; I, HDC

On-Site Storage Plan ; I, HDC

Operational Testing Plan ; G, HDC

SECTION 35 05 40.14 26 Page 11

Manifold Plating Procedure

Spill Protection, Controls And Countermeasures Plan (Testing) ; G, HDC, C

Hydraulic Cylinder Testing Plan ; G, HDC

Initial Conference

SD-02 Shop Drawings

SD-03 Product Data

Electrical Equipment ; G, HDC

Design and Performance Requirements ; G, HDC

Cleaning and Flushing ; G, HDC

Seals, O-Rings, and Bearing Material ; G, HDC

Rod Coating Data ; G, HDC

Component And Fluid Compatibility ; G, HDC

SD-05 Design Data

Packaging Details ; G, HDC

Nameplates ; G, HDC

Hydraulic Cylinders ; G, HDC

Cylinder Handling Device ; G, HDC

Hydraulic Power Unit ; G, HDC

Control Station ; G, HDC

Piping System ; G, HDC

Pipe Supports ; G, HDC

Stub Piston Rods And Couplings ; G, HDC

Miscellaneous Equipment ; G, HDC

3D Computer Model

SD-06 Test Reports

Shop Testing Report ; G, HDC

Pressure Testing Report ; G, HDC

Operational Testing Report ; G, HDC

Dimensional Verification Report ; I, HDC

SECTION 35 05 40.14 26 Page 12

Functional Test Report ; G, HDC

Cylinder Handling Device Load Test Report ; I, HDC

Post-Plating Quality Control Report ; G, HDC

Hydraulic Cylinder Testing Report ; G, HDC

Cleaning And Flushing Test Reports ; G, HDC

SD-07 Certificates

Erection Engineer ; G, HDC

Training Instructor ; G, HDC

Registered Professional Mechanical Engineer ; G, HDC

SD-10 Operation and Maintenance Data

Sample Training Course Materials ; G, HDC

1.4 DESIGN AND PERFORMANCE REQUIREMENTS

The Contract drawings indicate the general arrangement and conceptual design of the hydraulic power system and other pertinent features.

Finalize the design with selected hydraulic components and equipment in accordance with the requirements of this SECTION and with ISO 4413 .

1.4.1 Definitions

The following terms are used throughout this specification SECTION:

a. High Pressure - That part of the system between the outlet of each pump and the pressure side of the single action gate cylinders, including, but not limited to: All piping between pump outlets, supply distribution header, control manifolds, and all piping and hoses connected to the high pressure side of the cylinder.

b. Low Pressure - That part of the system between the return side of the single action cylinders to the pump inlet, including but not limited to: all piping and hoses between the the return side of the cylinder and the return header, return header piping, oil storage tanks, and pump supply piping.

c. Normal Operating Pressure - The pressure required to raise the gate under balanced head conditions.

d. System Rated Pressure - Maximum pressure in the system during regular operation. Pressure used for selecting catalog/off-the-shelf components.

1.4.2 System Summary

The following paragraphs provide a brief narrative of how the hydraulic power system is configured and operated. It is a summary and is not an inclusive description of all features or operating conditions.

The intake gate hydraulic system operates the intake gates for the 6 main

SECTION 35 05 40.14 26 Page 13 units. Each main unit has 3 intake gates. Intake gates are supported in each gate slot by a support beam and operated with one cylinder. The intake gates are connected to the cylinders by stub piston rods and couplings. All intake gates, support beams, stub shafts, and cylinders are interchangeable.

A centralized hydraulic power unit (HPU) is shared by all units.

Hydraulic fluid is distributed through a system of two headers. A hydraulic fluid reservoir tank is positioned on the intake deck and provides make-up fluid and storage capacity. Control stations at each unit are used to control the gates for that unit. Gates are raised using hydraulic pressure from the HPU and lower under gravity. Flow control valves at the control stations limit the closing speed.

The gates are typically operated using the local controls at the control stations. This Contract adds remote control, to the powerhouse control room, for an automated closure scheme.

Under normal operating conditions, the gates are suspended in the raised position using pressurized oil. The pressurization pump automatically activates based off pressure switches to ensure the gates do not drift under gravity.

1.4.3 Design Parameters

The principal design parameters for the hydraulic power system are as follows and were developed at the minimum operating temperature and utilizing the hydraulic fluid as specified:

a. System Rated Pressure: 3000 psi

b. Normal Operating Pressure: 2000 psi

c. Load Due to Crane Maximum Motor Torque: 568 kip

d. Minimum Cylinder Stroke: 47 feet - 4.75 inches, contractor to verify

e. Cylinder Piston Area (high pressure side): 143.5 square inches, minimum

f. Cylinder Maximum Outer Diameter: 26 inches

g. Lowering Flow Rate: To be determined based off cylinder dimensions and speed listed below.

h. Raising flow rate: 13 gpm, per gate, minimum

i. Lowering Speed:

1) Normal: 12 feet per minute (+/- 10%)

2) Cushion Zones: 7 feet per minute (+/- 10%)

3) Safety Orifice: 40 feet per minute (maximum)

j. Minimum Ambient Temperature: 0 degrees F

SECTION 35 05 40.14 26 Page 14

1.4.4 Allowable Stresses

1.4.4.1 Load Cases and Allowable Stresses

When selecting off the shelf components, size using the system rated pressure. For design of items not governed by a referenced code or specified otherwise, use all of the following load cases and allowable stresses:

a. Load Case 1 (LC1) - Stresses resulting from forces due to normal operating pressure of the system: 20 percent of the ultimate tensile strength of the materials involved.

b. Load Case 2 (LC2) - Stresses resulting from forces due to the the rated pressure of the system: 50 percent of the material yield strength.

c. Load Case 3 (LC3) - Stresses resulting from forces due to the maximum motor torque of the intake crane while raising the cylinder/intake gate assembly: 75 percent of the yield strength of the materials involved. The hoist load due to a maximum motor event is 568 kips. Note this load case only applies to the load path through the piston rod and hoist locking device when removing the cylinder gate assembly from the slot and is not applicable to the components.

1.4.4.2 Stress Concentration Factors

Use stress concentration factors where applicable. Reduction of allowable stresses to compensate for repeated cycles of loading is not required.

1.4.5 Corrosivity Environment Category

Design hydraulic cylinders, cylinder rods and components to meet the corrosivity category CX in accordance with ISO 9223 to meet anticipated atmospheric environment the cylinders and piston rods will be operating within.

1.4.6 Connections

1.4.6.1 Pinned Connections

Design pinned hydraulic cylinder connections for field assembly.

1.4.6.2 Shop Connections

Design shop connections for assembly by means of welding or by bolting.

1.4.6.3 Welded Connections

a. Design welded connections, for components not subject to being pressurized, in accordance with AWS D1.1/D1.1M except that provisions for repeated stress is not required.

b. Design welds for hydraulic cylinders in accordance with ASME BPVC.

c. Design welds for piping in accordance with ASME B31.1 .

d. U-stamp requirements per ASME BPVC are waived.

SECTION 35 05 40.14 26 Page 15

1.5 QUALITY ASSURANCE

1.5.1 Hydraulic System Designer Qualifications

All calculations and drawings for the hydraulic system and hoist, including the hoist locking device, stub piston rod, and couplings must be prepared, or fully reviewed, and stamped by a Registered Professional Mechanical Engineer ; submit qualifications for the engineer(s) who will be stamping these submittals. Additionally, each Professional Mechanical Engineer must minimum of five years experience designing the equipment or system(s) they are responsible for (e.g. the hydraulic cylinder designer must have five years of specific hydraulic cylinder design experience).

The submittal must include evidence or documentation, such as a resume.

1.5.2 Submittal Packages

1.5.2.1 Submittal Package General Requirements

Submit comprehensive and complete submittal packages for each of the following components or system of components:

a. Hydraulic Cylinders , including hoist locking device

b. Cylinder Handling Device

c. Hydraulic Power Unit

d. Control Station

e. Piping System including new high- and low- pressure headers

f. Pipe Supports

g. Stub Piston Rods and Couplings

For any equipment not covered by the above, submit Miscellaneous Equipment submittal package.

1.5.2.2 Submittal Package Contents

Submittal Packages must be complete and include all relevant information and data for the equipment being submitted. Submittal Packages that are not complete will be returned to the Contractor for corrections without further review. Submittal packages must include the following elements, at a minimum. The requirements for each element are described in the paragraphs that follow:

a. Drawings, including fabrication drawings, shop drawings, and/or schematics

b. Product data

c. Calculations

1.5.2.3 Initial Conference

For each Submittal Package identified above, the Contractor must schedule an Initial Conference. The purpose of the Initial Conference is to allow the Contractor opportunity solicit feedback on the design progress and

SECTION 35 05 40.14 26 Page 16 resolve any outstanding issues or questions prior to finalizing the design. The Contractor shall provide notification to the Government a minimum of 14 days prior to the proposed date.

Include the following in the notification, as applicable and for information only:

a. Draft submittals

b. 3-dimensional models in a format that is viewable/readable through an Internet browser.

c. Questions for the Government regarding the Contract Requirements

d. Potential variance requests including complete justification

Initial Conferences must be scheduled to last no more than 4 hours. The Contractor should assume that each conference will be held in a remote/virtual environment such as Microsoft Teams or Webex. The Contractor is responsible for keeping and publishing minutes from each conference. Meeting minutes shall be published within 24 hours of the meeting.

1.5.3 Drawings

1.5.3.1 General Drawing Requirements

In addition to the requirements in SECTION 01 33 00 SUBMITTAL PROCEDURES, the following requirements apply to all drawing packages that are submitted:

a. Provide a drawing index for each drawing package submitted.

b. Provide a bill of materials or parts list with each drawing package.

c. Drawing index and bill of materials must have a title block, border, and sheet number compatible with the drawing set.

d. For the bill of materials, provide a cross reference between manufacturer data and shop drawings.

e. Provide the weight of components and/or assemblies of components.

When components can be filled with hydraulic fluid, provide weights full and empty.

f. Symbology and terminology across ALL drawings and schematics must be identical and cohesive, regardless of whether they are prepared by the same supplier or sub-contractor.

1.5.3.2 Fabrication Drawings

Where fabrication drawings are required, they must provide the complete details for each component including materials of construction, dimensions, tolerances, machined surface finishes, connections, weld details, and coating requirements. All weld detail callouts must include annotation referencing the appropriate welding procedure specification, non-destructive examination requirements, and notation to differentiate shop welds from field welds.

SECTION 35 05 40.14 26 Page 17

1.5.3.3 Hydraulic Cylinder Drawings

Submit detailed assembly drawings for the hydraulic cylinders that show the following:

a. Longitudinal section through the cylinder showing the complete assembly.

b. Installation and connection details of the cylinder to the support beam and intake gate, including lifting procedure via the intake crane.

c. Installation and connection details of the cylinder to the supply and return piping.

d. Fabrication drawings for each component in the hydraulic cylinder.

e. Transportation, handling and lifting drawings, including proper support and restraints during shipping and transport as well as instructions to take cylinders from the horizontal-to-vertical position and vertical-to-horizontal position.

1.5.3.4 Hydraulic Power Unit Drawings

Submit detailed assembly drawings for hydraulic power units (HPU) showing the following:

a. General arrangement of components and outline dimensions of unit.

Label all valves and ports and identify all line sizes.

b. Detail drawings of the connection between the HPU and the piping system.

c. Detail drawings of the HPU control panel installation and orientation.

d. Fabrication drawings for each component in the HPU.

1.5.3.5 Piping Drawings

Submit drawings for all new piping and tubing systems that show the following:

a. General arrangement of new piping and appurtenances including new high and low-pressure headers, connections between the headers and the control stations, connections between the accumulators and the headers, connection between the new HPU and the headers, and connection between the headers and the hydraulic fluid storage tank.

Label all valves and ports and identify all line sizes.

b. Fabrication drawings for each new piping or tube segment.

c. Fabrication drawings for each new hose.

d. Fabrication and assembly drawings for new pipe supports.

1.5.3.6 Control Drawings

Submit detailed drawings for the new control stations that show the following:

SECTION 35 05 40.14 26 Page 18

a. General arrangement of the new control stations showing all components in their installed arrangement and orientation.

b. Detail drawings for of the control station installation.

b. Fabrication drawings for each component. Include section views of the manifold blocks to show all internal passageways.

1.5.3.7 Hydraulic Schematic

Submit hydraulic schematics for all portions of the hydraulic system.

Prepare schematics in accordance with ISO 1219-1 and ISO 1219-2 and the following additional requirements:

a. Show all, and clearly identify and label, hydraulic components including valves and pumps.

b. Indicate all setpoint and size parameters for each component.

c. The new hydraulic schematics must incorporate all existing components that will remain and all new or replaced components and devices. Clearly differentiate between new and existing components.

d. Where schematics are split over multiple drawing sheets, break lines or continuation lines must be clearly identified.

e. Provide a key or legend for each schematic that identifies all equipment included in that schematic.

1.5.3.8 Electrical Drawings

Provide electrical as-built and submittal drawings, as required per Section 26 05 00.00 26 , BASIC ELECTRICAL MATERIALS AND METHODS.

1.5.3.9 3D Computer Model

If 3D computer modeling is employed for the design of any component of the intake gate hydraulic system, submit the 3D Computer Model files for all modeled components and assemblies to the government. Submit the 3D Computer Model files in a file type compatible with government software, unless otherwise approved.

1.5.4 Product Data

Submit complete descriptive literature with drawings and specifications of each product or system of products provided. Product data literature shall include legible manufacturer's cut sheets and data sheets to clearly indicate physical construction, operation, mechanical, electrical and structural characteristics and associated hardware, as applicable.

For sheets with extraneous data, clearly indicate which data applies by crossing out non-applicable models, circling the correct options, etc.

Include manufacturer's catalog numbers and designations, and clearly cross-reference with shop drawings as appropriate.

For product data submitted for approval, clearly show conformance with these specifications, including, but not limited to product manufacturers' declarations of conformance to applicable technical standards. Product

SECTION 35 05 40.14 26 Page 19 data will be used for supporting approval of components shown or listed on the drawings.

1.5.5 Calculations

1.5.5.1 Calculation Requirements

All submitted calculations must show that the component or system of components conform the the requirements of the specifications. Submitted calculations must conform to the following requirements:

a. Write calculations in an explicit, step-by-step logical order with a full narrative description.

b. State all assumptions that are made.

c. Clearly define all equations, constants and variables, with sources cited.

d. Note all specified or assumed efficiencies and factors of safety.

e. Include free body diagrams, or sketches of each load case.

When FEA data is submitted, it shall be submitted in addition to, not instead of, the above calculations . FEA shall be presented in report format. FEA report shall include clear indication of all load scenarios, visual and narrative description of load location and application, boundary conditions / fixtures, global mesh attributes, detailed mesh attributes where mesh refinement is required, reasoning for mesh refinement, verification that actual material is consistent with material used in the model, narrative explanation of any peak stresses noted, and narrative explanation of any peak deflections noted. Submit electronic files of the model, preprocessing and post-processing files for any FEA performed.

1.5.5.2 Calculation Packages

In additional to the general requirements above, there are the following requirements for specific packages:

a. Hydraulic Power Unit Design Calculations including, pump sizing, piping selection, frame structural calculations, frame lifting point calculations.

b. Control Station Design Calculations, including sizing of flow paths/ports.

c. Piping Design Calculations including headers, gate piping, miscellaneous piping, and accumulator tanks installed on the headers.

1.6 COMPONENT AND FLUID COMPATIBILITY

1.6.1 General Compatibility Requirements

Any component that comes into contact with the hydraulic fluid must be rated by the component manufacturer for use with the class/type of fluid specified in this contract or satisfactory performance must be proven by testing. No corrosion, material deterioration, or functional impact of the component is to occur due to its exposure to the specified and provide

SECTION 35 05 40.14 26 Page 20 hydraulic fluid. Submit manufacturer's ratings and/or testing results as part of the applicable product data package(s).

Additional compatibility requirements specific to certain components are listed under the PARAGRAPHS for those component.

1.6.2 Manufacturer's Published Ratings

If the manufacturer has published ratings or catalog data that show compatibility with the specified fluid type, that published data may be submitted as sufficient proof of component compatibility.

1.6.3 Compatibility Testing

If manufacturer's published data regarding compatibility does not exist, perform compatibility testing to prove compatibility. Relevant tests include, but may not be limited to: material absorption, swell, and degradation (including corrosion). Testing must be performed in accordance with ASTM or other similar published test methods. Clearly indicate what standard tests were used to prove compatibility, including what metrics were used to define the range of allowable/acceptable results.

1.7 QUALITY CONTROL

In addition to the requirements of Section 01 45 04.00 28 CONTRACTOR QUALITY CONTROL, establish and maintain quality control for operations to assure compliance with Contract requirements and maintain records of quality control for all materials, fabricated parts, equipment, and construction operations. In addition, establish and maintain surveillance for quality control over sub-contractors, suppliers, or manufacturers. The quality control includes, but is not limited to, the following:

a. Materials and workmanship.

b. Manufacture and installation of the piping, hydraulic cylinder assemblies power units and manifolds.

c. Cleaning and flushing.

d. Shop assembly and tests.

e. Field erection and tests.

f. Damage and defects.

Submit a copy of these records and tests, as well as the records of corrective action taken, to the Government.

PART 2 PRODUCTS

2.1 MATERIALS AND MECHANICAL EQUIPMENT

2.1.1 General

Provide materials and mechanical equipment in accordance with the requirements as indicated or specified, and if not specified, furnish materials and mechanical equipment of the best commercial grade quality suited to the intended use and as approved. All electric motors, SECTION 35 05 40.14 26 Page 21 hydraulic pumps, hydraulic cylinders, valves and similar items and/or accessories, of the same type and size, to be the products of the same manufacturer, unless otherwise approved. Permanently display the manufacturer's name, address, and catalog number on a nameplate securely attached to each item of equipment.

For all surfaces in contact with the hydraulic fluid, remove any and all fabrication coatings and/or residues. This includes, but is not limited to, mill scale, coatings or products used as part of the raw material fabrication process, and anti-corossive coatings.

2.1.2 Standard Products

The standard product of any reputable manufacturer regularly engaged in the commercial production for at least 2 years prior to this solicitation 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 HYDRAULIC FLUID

All hydraulic fluid used to fill, including temporary fills, must be in accordance with SECTION 35 05 40.14 26 HYDRAULIC FLUID. SECTION 35 05 40.14 26 HYDRAULIC FLUID allows for different viscosity grades. The Government has a preference to use the higher viscosity grade, provided performance in the ambient conditions and application is acceptable.

2.3 HYDRAULIC CYLINDERS

2.3.1 General Design and Configuration

Provide 19 (1 is designated as a spare) complete cylinder assemblies that meet the requirements of the following paragraphs and the following general requirements:

a. Cylinders are to be single acting, gravity extend, pressure retract, mill-type designed to meet the requirements of the criteria stated in PARAGRAPH: "Design Parameters".Design for assembly of the support beam and cylinder with the cylinder in both the vertical and horizontal orientations.

b. Cylinder exterior dimensions must conform to what is shown on the Contract Drawings and required by this SECTION.

c. The cylinder must be a "rod-up" design such that the rod is stationary and the outer cylinder moves. Configure the cylinder such that the rod gland is above EL. 738.5 when the cylinder and support beam are installed in any gate slot.

d. Design cylinders and integrated appurtenances to be partially submerged and operate under at least 100 feet of water.

e. Hydraulic Connections: All connection points to the hydraulic lines must be located on stationary components of the hydraulic cylinder assembly. Drill, tap, and surface ports to receive SAE Code 61 flanges.

f. Safety Orifice: Equip the high-pressure cylinder line with an orifice such that if there is a total loss/blowout of the high

SECTION 35 05 40.14 26 Page 22 pressure hose, the gate does not free fall. Size the orifice to produce the speed listed in PARAGRAPH: "Design Parameters".

g. Cushion: Cylinders must incorporate a mechanical cushion feature for the last 2 feet of travel when extending. The cushion must limit flow rate such that the gate travels no faster than the speed specified in PARAGRAPH: Design Parameters (assume hydraulic fluid is at design pressure). Cushion must be designed so that it remains effective, even in the event of a total hose loss/blowout.

h. Provide an air bleed port on the top of each cylinder. Tap each port to receive 7/16-20-SAE bleed valves.

i. Provide a drain port on the bottom of each cylinder. Provide a plug for each port. Ports must be a minimum of 1 inch, nominal, in diameter and tapped with SAE threads. NPT threads are not acceptable.

j. All exterior surfaces of the hydraulic cylinders except the piston rod must be painted in accordance with Section 09 97 02.13 26

PAINTING - STEEL STRUCTURES.

k. Provide a lifting device for the cylinder and support beam assembly to adapt the existing intake gate lifting beam to the cylinder/support beam. Provide the lifting device in accordance with SECTION 41 22 13.75 26 NEW SUPPORT BEAMS AND LIFTING DEVICES. Cylinder design must be coordinated with the lifting device design.

2.3.2 End Configurations

2.3.2.1 Rod End

Design the rod end in accordance with the following requirements:

a. The rod end must connect to the new support beams through the cylinder support.

b. The rod end design must not rely entirely on friction to hold the rod/cylinder vertically in place.

c. All threads must be cut entirely in material that is corrosion resistant (e.g. stainless steel). Threads cut into the carbon steel material are not acceptable.

d. The rod end must have provisions for the high and low pressure hydraulic connections.

2.3.2.2 Cylinder End

Design the cylinder in end accordance with the following requirements:

a. The cylinder end must connect to the new stub piston rod.

b. Mating surfaces between the end connection and stub-piston rod must be stainless steel.

c. The connection must be designed to be disassembled in the field such that when the cylinder is suspended by the crane, the cylinder can be detached from the stub piston rod using only hand tools.

SECTION 35 05 40.14 26 Page 23

2.3.2.3 Cylinder Support

The cylinder rod end must connect to the New Support Beam through a cylinder support. The cylinder support must use the bolt-hole circle on the New Support beam that is shown on the contract drawings. It is acceptable for the rod end and cylinder support to be a single assembly or separate components. The design of the cylinder support must allow for the support beam to be removed from the rod end without having to disassemble pressurized portions of the cylinder.

2.3.3 Cylinders

Cylinders for hydraulic cylinder assemblies must be provided in accordance with the following requirements:

a. Make cylinders out of steel meeting one of the following options::

1) Option A: Rolled and welded steel plate in accordance with ASTM A516/A516M , Grade 70, Seamless pipe in accordance with ASTM A106/A106M , or equivalent material as approved, and welded, forged flanges in accordance with ASTM A105/A105M or equivalent material as approved.

2) Option B: Provide centrifugal cast steel shell in accordance with ASTM A216/A216M , Grade WWC or equivalent material as approved, and welded, forged flanges in accordance with ASTM A105/A105M , Class 70 or equivalent material as approved, or cast from ASTM A216/A216M , Grade WWC steel or equivalent material as approved.

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

b. The interior of the finished cylinder to be honed to the dimensions, tolerances and surface finish shown on the shop drawings.

c. The finished wall thickness not to be less than what is calculated in the design calculations.

d. Weld flanges to the cylinder parallel with each other and perpendicular to the cylinder center line.

e. Stress relief heat treat the cylinder after completion of all welding.

f. The assembled cylinder to be of such straightness that the piston and rod move smoothly without any indication of binding or tight spots.

g. Perform weld inspection of the cylinders in accordance with Section

40 05 13.96 26 WELDING: PIPING AND PRESSURIZED SYSTEMS.

2.3.4 Piston Rods

2.3.4.1 Piston Rod General Requirements

Piston rods for hydraulic cylinders must meet the following requirements:

a. Make rod rods from carbon steel meeting the requirements of ASTM A108, Type C 1045 or Type CR 4140 or equivalent material as

SECTION 35 05 40.14 26 Page 24

G4EDDMTJ

Line approved. Outer surface coating must be weld overlay or laser clad type. The coating material must be certified and formulated to consist of a metal alloy to meet corrosivity category and designed and applied by the cylinder manufacturer.

b. If rods are made from two or more pieces, joints must be made with full penetration welds. Perform weld inspection of the rods in accordance with Section 40 05 13.96 26 WELDING: PIPING AND PRESSURIZED

SYSTEMS.

c. Submit certified test reports for both the rod material and performance requirements as specified.

2.3.4.2 Piston Rod Coating Data

All rod coatings must meet or exceed the minimum test criterion as stated in Table 1).

Submit rod coating data that includes details compliance with the following tables as well as any additional information required to prove compliance with the requirements of this SECTION.

Table 1: Welded Overlay (Laser Cladding) Coating Requirements

No. Test Criterion Remarks

1. Welding Procedure Qualification (WPQR) for the application of technical coatings

Manufacturer to be ISO 9001 certified and or have produced coatings of the type and application specified for a minimum of 5 years with a written quality documentation procedure in place during that period.

Welding to be performed in accordance with ISO 15614-7 or ASME BPVC SEC IX or both.

Implementation and certification performed by the manufacturer. The WPQR should address such items as Personnel Qualification for Coating application, Calibration of equipment and service maintenance records, Material Certificates with chemical composition, Process parameter specification thresholds, Dimensional control, Inspection/ Acceptance.

2. Microscopic examination (cross section)

0.1% defects allowed in accordance with ISO 5817 Table 1

3. Chemical composition

Metal alloy Powder certificate provided as a shop drawing submittal for approval

4. Coating thickness

Manufacturer's stated range for the certified coating system.

Conduct pre-and post-process diameter measurements. Additional tests may be performed of test samples produced at time of fabrication may be submitted.

SECTION 35 05 40.14 26 Page 25

No. Test Criterion Remarks

5. Hardness In accordance with ISO 15614-7 as recommended by manufacturer and approved.

>300 HV 5 Vickers in accordance with ISO 6507 -1 or 290 Brinell Hardness

Maximum hardness depends on substrate material. Care must be taken to keep the heat-affected zone (HAZ) soft enough to avoid brittleness and potential delamination with the substrate

6. Corrosion testing for low corrosivity categories SDCT 4000 hours

Perform Corrosion Testing in accordance with Manufacturer's standard testing procedures. Submit test results.

Electrochemical test or salt droplet corrosion test as required for low corrosivity category.

7. Corrosion testing for high corrosivity categories C5 and CX by

ASTM G48

ASTM G48-C/72h >60C Utilize corrosion testing per manufacturer testing method or ASTM G48. No pitting at 60C

SECTION 35 05 40.14 26 Page 26

No. Test Criterion Remarks

8. Surface finish Acceptable minimum and maximum roughness values to be determined by cylinder manufacturer and seal manufacturer for the intended cylinder operating environment as specified and using the manufacturer's published data.

Quantify surface finish in terms of Ra, Rz, and Rmr.

All surface finish parameters in accordance with ISO 4287 and ISO 4288 .

No cracks, blisters, holes, or discoloration visible with naked eye are allowed.

No defects >8microinches allowed.

No defects through coating and into base material allowed.

9. Dynamic bending (3-pt)

Perform Dynamic Bending (3-Pt) in accordance with Manufacturer's standard testing procedures. Submit test results. Achieve 400MPa bending stress.

2.3.5 Pistons

Make pistons from cast iron meeting the requirements of ASTM A536, Grade 80-55-06 or 10-50-05 or equivalent material as approved.

2.3.6 Seals, O-Rings And Bearing Materials

2.3.6.1 Serviceability

The seals and bearings specified in this section must be field serviceable and not require specialty jigs, tools, or to be returned to the cylinder manufacturer.

2.3.6.2 Material Compatibility

Design and provide seals, O-rings, and bearing materials to be compatible with the specified hydraulic fluid. Each material in use with the

SECTION 35 05 40.14 26 Page 27 hydraulic cylinder to be tested to verify the chemical resistance and hydraulic fluid compatibility. Conduct testing in accordance with ISO 1817 to measure changes in hardness, tensile strength, and elongation to satisfy the requirements of the cylinder and seal manufacturers. Submit for Government approval seals, O-rings and bearing materials.

Submit seals, O-rings, and bearing material properties in accordance with the minimum requirements as specified in manufacturers standard…