T468-6.2.

3 - Hydraulics Actuators:

This specification describes a complete packaged hydraulic actuator. The actuator

assembly is an integrated package of hydraulic cylinder and electric motor driven
hydraulic power unit. The actuator assembly shall be provided in a cardanic ring swivel
mount with all attachment pieces.

A. Hydraulic Power Units

1. Each actuator shall have an integral 2HP hydraulic power unit of simple design
and substantial construction. Units must be designed to withstand direct rain and other
effects of a wet marine environment. Arrange parts to permit easy erection, adjustment,
and replacement of typical maintenance parts. Arrange parts to permit easy access for
inspection, lubrication, maintenance and repairs.
2. Provide dual hydraulic pumps with single input drive shaft. Pumps must be
positive displacement type capable of bi-directional rotation. Do not use solenoid valves
to change direction of flow. Provide pumps with the following:
a. Rated for continuous duty at 3000 psi or higher
b. Maximum total displacement of both pumps at 3gpm
c. The high flow pump shall be capable of approximately 2gpm at 900psi.
d. The low flow pump shall be capable of approximately 1gpm at 2900psi.
e. Drive pumps with a 1200rpm electric motor. Electric motor shall be
TEFC with seals and rain shield to prevent moisture from entering the
motor.
3. Each power unit to have a 4-gallon stainless steel reservoir with sight gauge.
Fabricate reservoir from ASTM A276 type 316 - ¼” plate. The reservoir must be sealed
against the ingress of water and capable of containing the fluid even at 90-degree rotation
of the entire actuator.
4. Supply all required valving to provide two stage high/low system performance
in both directions of pump rotation. Factory preset all necessary relief, sequence, and
check valves to allow an independent maximum relief setting protection in each direction
of pump flow. Valves should be screw-in cartridge type arranged in a compact aluminum
manifold. Valve stem adjusting screws shall have a stainless-steel cap to protect the
adjusting screw from corrosion.
5. Unit to have a return filter with visual clogging indicator. Filter elements must
have at least a10-micron rating of Beta 10 = 200 or better.
6. Hydraulic fluid shall be mineral oil type AW32.
7. Provide low level shut down float switch.
8. Provide two pressure gauges clearly visible for maintenance purposes. Gauges
shall be 2.5-inch glycerin filled type in stainless steel housing.
9. Supply with easily replaceable water removal breather

B. Hydraulic cylinders
1. Provide hydraulic actuators with double trunnion cardanic ring gimbal type
mounting arrangement as shown in the plans. Cylinder rods shall be capable of moving
up to 20 degrees off centerline in any direction. Submit complete details and calculations
for cylinder and mounting arrangement as described below.
 2. Hydraulic cylinders shall be of heavy duty mill type design conforming to
AASHTO Specifications and ASME B31.1 of the mid trunnion mounting type shown in
the Plans. Provide cylinders’ design rated for a minimum of 3000 PSI. Cylinders shall
have 2.5” bore, 20” stroke, and 1.38” rod diameter as indicated in the plans with SAE
ports. Provide cylinders with the cylinder head and end cap bolted to the body flange.
Screwed heads and caps are not allowed.

3. Design and construct cylinder actuator piston rods to provide a minimum

Factor of Safety of 3.0 against buckling per AASHTO Buckling requirements. Factors of
Safety shall be based on a maximum working pressure equal to the maximum pressure
protection setting at the cylinder relief valves. Provide piston rods of high strength carbon
steel with corrosion resistant nitriding surface finish or nickel chrome overlay. Standard
chrome plated rods are not acceptable. Alternate rod material of 17-4 stainless steel is
acceptable if it can meet buckling requirements. Submit calculations to support rod
selection per above requirements.

4. Rod Seals and Bearings: Provide a sealing system that includes dynamic seals
capable of near zero leak at both low and dynamic high pressure. Suitable wear-rings or
gland bushings shall be provided to insure proper guidance of the rod, to insure
alignment, and provide ample bearing area to prevent side-loading.

5. Provide hydraulic cylinder with a rod eye that is a non-lubricated type spherical
bearing with stainless steel housing.

6. Provide a cardanic ring mounting support bracket that will accept the trunnion
mounted hydraulic cylinder. Cardanic ring to be fabricated from A572 Grade 50 steel
with composite bearings that do not require lubrication. Cylinder rod must be capable of
actuating up to 20 degrees off centerline in any direction. Submit design calculations
showing cardanic ring and bearings can operate with a minimum safety factor of 2 based
on cylinder design ratings above.

7. Complete actuator to be primed and finish painted with two-part marine epoxy
coating.

8. Shop testing of the actuator to 3000psi in both directions is required.

C. Plumbing and Fittings

1. Mechanical connections will be used that incorporate O-rings as the primary
pressure sealing component. All exposed fittings and tubing shall be 316 stainless steel
and use SAE straight thread with O-ring. Pipe thread NPT type fitting connections are not
allowed.
 2. Provide 3/8” stainless steel braided cover flexible hose to isolate cylinder
movement from HPU. Stainless braided hose will be of the proper SAE rating, consistent
with working pressures of 3000 psi.

D. Hand Pump Integral (if required)

1. Provide a new auxiliary hydraulic hand pump as an integral part of the actuator
for manual operation in the event of hydraulic power unit failure. Hand pump shall have
its own relief valve set at 2000 psi and four-way directional control valve such that it can
cycle the hydraulic actuator in both directions. Provide 316 stainless steel connections
between the auxiliary hydraulic hand pump and system lines. Working pressure ratings of
all disconnects, fittings, and hoses shall be 3000 psi.