Folsom Dam Joint Federal Project (JFP) Hydraulic Cylinder Repair (HCR)

This project replaces existing hydraulic cylinders and rods for Flood protection spillway gates due to early signs (cracking of top coating) of advanced corrosion. The scope of work will include deconstruction of the (12) existing hydraulic cylinders and removal of the spare cylinder, manufacturing, transporting, providing off-site storage for up to two years, installing and testing twelve (12) replacement hydraulic cylinders assemblies and providing one spare, and integrating the control system. The existing cylinder rods are 8-inch in diameter and 40 feet long. The design of the new cylinders and rod systems will be of a performance-based requirement and need to accommodate existing structure tolerances. The replacement hydraulic cylinder assemblies must be compatible with the existing gate connection points, cylinder trunnion supports, hydraulic cylinder connections for power, controls, hydraulic fluid piping, and rod position system power and signal wiring as well as the PLC input card. The new hydraulic cylinder rod coating will be laser cladding/weld overlay over groove-based hall-effect contactless linear measurement sensor and transducer for position measuring system. A critical aspect of the hydraulic cylinder assembly design is thorough quality assurance/quality control (QA/QC) procedures during manufacturing, transportation, installation, control system integration and cylinder testing.