9-I. Appendix A - Specifications for Water Treatment Plant Valve Replacement Materials.pdf

32220-039 40 05 57-1 WM1 VALVE & GATE ITB

SECTION 40 05 57

VALVE OPERATORS AND ELECTRIC VALVE ACTUATORS

PART 1 – GENERAL

1.01 THE REQUIREMENT

A. Reference Section 40 05 64 – Rectangular Butterfly Valves for additional information on valves and operators/actuators.

B. Valve operators and electric valve actuators shall be designed to unseat, open or close, and seat the valve under the most adverse operating condition to which the valves will be subjected.

C. Operator mounting arrangements shall be as indicated on the Drawings or as directed by the manufacturer and/or Engineer. There shall be no mounting restrictions on the electric valve actuator.

D. In this specification section, the term “manufacturer” refers to the entity manufacturing the rectangular butterfly valve.

E. The valve operators and electric actuators shall be the full and undivided responsibility of the manufacturer in order to ensure complete coordination of the components and to provide unit responsibility.

PART 2 – PRODUCTS

2.01 GENERAL

A. Manual operators and electric actuators shall be provided as indicated in the schedule at the end of Section 40 05 64 – Rectangular Butterfly Valves

B. Quarter turn valves 8” and greater in size shall have geared operators. Gate valves 14” and greater in size shall have geared operators.

C. Operators/actuators shall be furnished with conservatively sized extension bonnets, extension stems, or torque tubes, and all required appurtenances required for a complete installation. Operators furnished with extension bonnets shall include stainless steel extension stems, or stainless-steel torque tubes.

2.02 MANUAL OPERATORS

A. Manual operator type shall be as indicated in the schedule at the end of Section 40 05 64 – Rectangular Butterfly Valves.

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B. Manual operators shall be rigidly attached to the valve body unless otherwise specified.

C. All operators shall turn counter-clockwise to open and shall have the open direction clearly and permanently marked.

D. Valve operators shall be designed so that the force required to operate the handwheel, lever, or chain (including breakaway torque requirements) does not exceed 80 pounds applied at the extremity of handwheel or chainwheel operator. Design pressures for sizing of valve operators shall be at least 200% of the maximum differential pressure as indicated in the schedule at the end of Section 40 05 64 – Rectangular Butterfly Valves.

E. Handwheels for valves operators shall not be less than 18 inches in diameter. The maximum diameter of any handwheel shall not exceed 24”.

F. Geared manual operators shall be of the worm gear, traveling nut or scotch yolk type except manual operators for butterfly valves 18-inch in diameter or larger which shall be worm gear, unless otherwise indicated in the individual valve specification. Gear operators shall be of the worm gear or bevel gear type. Gear box designs incorporating end of travel stops in the housing shall be equipped with AWWA input stops. Each gearbox shall require a minimum of 10 turns for 90 degree rotation or full valve stem travel and shall be equipped with a mechanical valve position indicator.

2.03 ELECTRIC VALVE ACTUATORS

A. Electric Actuators shall be open/close service.

1. Valve actuators shall be manufactured by Harold Beck & Sons, Inc. of Newtown, PA. No other manufacturers will be accepted.

B. Performance Requirements

1. The actuators shall be designed for indoor and outdoor service and shall be capable of mounting in any position.

2. Torque capacity of the actuators shall be sufficient to operate the valves with the maximum pressure differential, as indicated in the schedule at end of Section 40 05 64 – Rectangular Butterfly Valves, with a safety factor of 1.5.

3. Operating time for full limits of travel shall be not more than 2 seconds per inch diameter of the valve, +/- 50 percent through 20 inches; +/- 30 percent for valves 24 inches and larger. Operating time shall not be less than 60 seconds for all modulating valves.

4. Actuators shall be capable of operating in ambient temperatures ranging from 0 degrees F – 160 degrees F.

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5. For open/close (non-modulating) actuators, the gearing, motor and contactor shall be capable of 60 starts per hour without overheating.

C. The actuators shall include, in one integral housing, individual compartments for the motor, gearing, wiring terminals, and control circuits. The terminal compartment shall be separated from the inner electrical components of the actuator by means of a watertight seal. The inner seal shall protect the motor and all other internal electrical elements of the actuator from entrance of moisture and dust when the terminal cover is removed.

Double cartridge shaft seals shall be provided on the hand wheel and output shafts for weatherproof protection. All external fasteners shall be stainless steel. Compartments shall be provided with moisture and dust-proof rigid cast covers meeting NEMA 6, certified to submergence in 6 ft of water for 30 minutes. Actuators located in classified areas shall be suitable for use in Class 1, Division 1, Group D environments.

D. The actuators shall be provided with externally operable and lockable 120VAC circuit breakers integral to the control housing

E. All gearing shall be hardened alloy steel or bronze and shall be rated at twice the output torque of the operator and shall be designed to withstand the stall torque of the motor without failure. Output drive gearing shall consist of a worm shaft and worm gear pinion operating in an oil bath. The worm gear pinion shall be alloy bronze. Worm gear drive shall be self-locking to prevent creeping of the valve disc in an intermediate position.

Heavy-duty grease shall protect gearing and sealed ball bearings of the main shaft for five years without changing. Motor reduction gearing shall be spur or planetary gearing and shall allow for field repair and change in gear ratio. For quarter turn applications, overtravel of the operator shall be prevented by internal mechanical stops cast into the actuator.

F. A mechanical dial position indicator shall be furnished to continuously indicate the position of the valve at and between the fully open and fully closed positions. The indicator shall be driven by gearing driven off of the main worm gear pinion and shall operate when the actuator is in either the electrical mode or manual mode.

G. A handwheel shall be permanently attached for manual operation. A gear assembly shall be provided between the handwheel and the worm shaft if required to reduce the force necessary to operate the handwheel to less than 40 pounds. A positive declutch mechanism shall engage the handwheel when required. When the actuator is set in the declutched position for handwheel operation, it shall return automatically to electric operation when actuator motor is energized. The handwheel shall not rotate during electric operation nor shall a fused motor prevent handwheel operation.

H. The drive motor shall be specifically designed for actuator service and shall be characterized by high starting torque and low inertia. Motors shall be 120 volts, single phase, 60 Hz AC reversible squirrel cage induction type motors. Motors shall be totally enclosed, non-ventilated, with NEMA Class F insulation minimum and a maximum

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continuous temperature rating of 120 degree C (rise plus ambient). A space heater shall be provided in the motor compartment. The electric motor shall have a time rating of at least 15 minutes at 104°F (40°C) or twice the valve stroking time, whichever is longer, at an average load of at least 33% of maximum valve torque. Motor bearings shall be permanently lubricated by premium lubricant. The motor shall have plug and socket electrical connection to facilitate easy removal and replacement. The actuator shall include a device to ensure that the motor runs with the correct rotation for the required direction of valve travel with either phase sequence of the three-phase power supply connected to the actuator. The motor shall include single phase protection. A suitable thermal protection device shall be incorporated in the motor or motor starter circuits, connected to a tripping device. Fast acting fuses shall be provided to protect solid state components. The motor shall be capable of starting against the rated load in either the open or close direction when voltage to the motor terminals is plus or minus ten (10) percent of nameplate rating.

1. Open/Close actuators shall be furnished with electro-mechanical reversing starters.

I. Leads from the motor shall be brought to the control circuit (limit switch) compartment without external piping or conduit box. An adequately sized space heater shall be installed in the control circuit compartment to aid in the prevention of damage resulting in from condensation. The following items shall be located in the control circuit compartment.

1. Torque limit switches shall be provided to de-energize the motor control circuit in the event of a stall when attempting to unseat a jammed valve and when torque is exceeded during valve travel. Each actuator shall have an open direction torque switch and a close direction torque switch. The torque switches shall be mechanically operated and able to be set in torque units. Torque switches shall be calibrated prior to the actuator’s assembly to the valve.

2. Travel limit switches shall be provided to de-energize the motor control circuit when the actuator reaches the limits of travel in the open and close directions.

The limit switch drive shall be of the counter gear type and “in step’” with the actuator output drive at all times in either the electrical or manual mode of operation. A minimum of six (6) contacts, three (3) normally open and three (3) normally closed, shall be supplied at each end of valve travel. Four (4) additional contacts shall be provided to report end of travel or any desired position between ends of travel.

J. The electrical terminals shall be housed in a double sealed terminal compartment isolated from the rest of the actuator components. The actuators shall be designed to operate from a single 120VAC, 1-phase source. The actuators shall be furnished with fuses inside of the terminal compartment. A quantity of two – ¾ inch NPT conduit entries shall be furnished.

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K. Actuators shall contain wiring and terminals for the following control functions. All dry contacts shall be rated for 5A at 250VAC.

1. Open, Close, and Stop commands from external dry contacts (utilizing internal 120VAC power supply) and/or from an external signal of 12V to 120V. The inputs for the open, close, stop signals shall be field selectable to be respond to either maintained or momentary remote signals. In momentary mode, the actuator shall have internal latching circuitry that causes the operator to drive the valve to its limit of travel upon receipt of the momentary contact signal unless a stop signal is received.

2. Emergency override input from a normally closed or normally open contact. The actuator shall either open or close (field selectable) upon receiving the emergency override input.

3. Remote Local-Off-Remote selector switch, Open/Close pushbuttons, and Open/Closed pilot lights for a remote manual control station (see below). The remote Local-Off-Remote selector switch and Open/Close pushbuttons shall be a dry contact input to the actuator control circuitry. The Open/Closed pilot lights shall be powered from the valve actuator control power.

4. Four (4) unpowered contacts shall be provided which can be selected to indicate valve “Opened” and “Closed” position, “Remote” status of the actuator, and fail status of the actuator. The fail status contacts shall activate upon motor overtemperature and actuator overtorque as a minimum.

L. Local Controls

1. Actuators shall be furnished with a Local-Off-Remote selector switch; Open, Close, and Stop pushbuttons for local control; a red lamp indicating closed and a green lamp indicating open. L-O-R switch shall be padlockable in any of the three positions.

a. When the LOR is in the “Local” position, open/close control shall be by the open and close pushbuttons on the actuator. The stop push button shall stop the actuator travel.

b. When the LOR is in the “Off” position, the actuator shall not operate.

c. When the LOR is in the “Remote” position, the actuator shall be controlled by remote inputs from the PLC or from the remote manual controls station.

2. The local controls shall be arranged so that the direction of travel can be reversed without the necessity of stopping the actuator.

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PART 3 – EXECUTION

3.01 SHOP TESTING

A. Shop testing shall include the following requirements:

1. Conduct a complete functional check of each unit. Correct any deficiencies found in shop testing prior to shipment.

2. Submit written certification that:

a. Shop tests for the electrical system and all controls were successfully conducted;

b. Electrical system and all controls provide the functions specified and required for proper operation of the valve operator system.

3. Each actuator shall be performance tested and individual test certificates shall be supplied free of charge. The test equipment shall simulate each typical valve load and the following parameters should be recorded:

a. Current at maximum torque setting

b. Torque at maximum torque setting

c. Flash Test Voltage

d. Actuator Output Speed or Operating Time

e. In addition, the test certificate should record details of specification, such as gear ratios for both manual and automatic drive, closing direction, and wiring diagram code number.

f. Verification of actuator torque rating with valve.

END OF SECTION

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SECTION 40 05 58

GATE OPERATORS

PART 1 – GENERAL

1.01 THE REQUIREMENT

A. Reference Section 40 05 59.23 – Fabricated Stainless-Steel Slide Gates for additional information on gates and operators/actuators.

B. Gate operators and electric gate actuators shall be designed to unseat, open or close, and seat the gate under the most adverse operating condition to which the gates will be subjected.

C. Operator mounting arrangements shall be as indicated in the schedule at the end of Section 40 05 59.23 – Fabricated Stainless-Steel Slide Gates. There shall be no mounting restrictions on the electric gate operator.

D. In this specification section, the term “manufacturer” refers to the entity manufacturing the fabricated stainless-steel slide gate.

E. The gate operators and electric actuators shall be the full and undivided responsibility of the gate manufacturer in order to ensure complete coordination of the components and to provide unit responsibility.

PART 2 – PRODUCTS

2.01 GENERAL

A. Manual operators shall be provided on all gates.

B. Manual operators shall be mounted on either a floorstand or yoke mounted as specified in the schedule in in Section 40 05 59.23 – Fabricated Stainless-Steel Slide Gates.

1. Floorstands shall consist of a cast iron or stainless steel pedestal designed to position the input shaft or handwheel approximately 36inches above the operating floor. Floorstands shall be of the straight design as specified herein or as shown on the Drawings.

C. All operators/actuators shall be provided with a clear, butyrate plastic rising stem cover to protect the rising stem from moisture, dirt, and damage.

1. The stem cover shall not discolor or become opaque for a minimum of five (5) years after installation.

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2. "Fully Open" and “Fully Closed" positions shall be marked on each cover with mylar labels.

3. Covers shall be graduated in one (1) inch increments.

4. The top of the stem cover shall be closed and the bottom shall be designed for easy field mounting to the gearbox.

5. The bottom of the stem cover shall be designed to mount to the gearbox in such a way that all moisture is drained out to protect the stem and gearbox. Accumulated moisture of any amount on top of the gearbox inside the stem cover is unacceptable.

2.02 MANUAL OPERATORS

A. Manual operators shall be provided by the gate manufacturer. Manual operators shall be hand-crank operated as specified in the schedule in Section 40 05 59.23 – Fabricated Stainless-Steel Slide Gates.

1. Manual operation shall require no greater than a 40 pound pull on the crank or handwheel with the specified operating head on the gate.

2. Manual operators shall be provided with a threaded cast bronze lift nut to engage the operating stem. Tapered anti-friction roller or ball thrust bearings shall be provided above and below a flange on the operating nut to support both opening and closing thrusts.

3. Lubricating fittings and extensions shall be provided for the lubrication of all gears and bearings.

4. An arrow with the word "open" shall be permanently attached or cast on the floorstand, benchstand, or handwheel indicating the direction of rotation to open the gate. Unless otherwise noted, all operators shall turn counter-clockwise to open.

B. Hand-crank operated type manual operators shall have either single or double gear reduction depending upon the lifting capacity required.

1. Crank operators shall be suitable for operation by a portable gate operator.

2. Gearing shall be steel or cast iron with machine cut teeth designed for smooth operation.

3. The pinion shafts on crank-operated floorstands, either single or double, shall be stainless steel, and supported on tapered roller bearings.

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4. All components shall be totally enclosed in a cast iron weather-proof housing with cover.

5. Positive mechanical seals shall be provided on the operating nut and the pinion shafts where they extend from the cast iron case or gear box to retain lubricant and to exclude moisture and dirt.

6. The removable crank shall be cast iron with a revolving brass grip.

PART 3 – EXECUTION

3.01 SHOP TESTING

A. Shop testing shall include the following additional requirements:

1. Conduct a complete functional check of each unit. Correct any deficiencies found in shop testing prior to shipment.

2. Submit written certification that:

a. Shop tests for the electrical system and all controls were successfully conducted;

3. Each actuator shall be performance tested and individual test certificates shall be supplied free of charge. The test equipment shall simulate each typical gate load and the following parameters should be recorded:

a. Current at maximum torque setting

b. Torque at maximum torque setting

c. Flash Test Voltage

d. Actuator Output Speed or Operating Time

e. In addition, the test certificate should record details of specification, such as gear ratios for both manual and automatic drive and closing direction..

f. Verification of actuator torque rating with gate.

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SECTION 40 05 59.23

FABRICATED STAINLESS-STEEL SLIDE GATES

PART 1 – GENERAL

1.01 THE REQUIREMENT

A. Furnish and deliver all fabricated stainless-steel slide gates complete with all accessories, spare parts, mountings, anchor bolts and other appurtenances as specified herein and as required for a complete and operating installation. The gates and appurtenances shall be supplied in accordance with the latest edition of ANSI/AWWA C561 Fabricated Stainless-Steel Slide Gates, except as modified herein. Leakage for stainless steel gates shall be restricted to 0.05 gpm/ft or less of the seal perimeter at the design seating head and the design unseating head, which is half the allowable leakage rate listed in the latest revision of AWWA C561.

B. Refer to the schedule at the end of this specification section for further detail on gate location, dimensions, design criteria, number required, etc.

C. Manual and electric gate actuators (operators) shall be as specified in Section 40 05 58 Gate Operators and Electric Gate Actuators.

D. In this specification section, the term “manufacturer” refers to the entity manufacturing the fabricated stainless-steel slide gate.

1.02 WARRANTY

A. Equipment and material, including the actuators (manual and electric) shall be guaranteed to be free from defects in workmanship, design, and/or materials for a period of five (5) years.

B. Warranty period shall start on the date that the particular equipment and material is installed and successfully completes field testing by others or one hundred eighty (180) days after delivery, whichever is earlier.

C. Within the warranty period, the manufacturer shall repair or replace any component which is defective or showing undue wear, or replace the entire gate with a new unit if the mechanical performance is unsatisfactory. When performing such remediation, the Company shall furnish all parts, materials, labor, etc. and bear 100% of the costs to do so for at least the first year of the warranty period. These repair/replacement costs may be linearly prorated for the second year of the warranty period.

D. The Company shall guarantee to the City that all equipment offered, or that any process resulting from the use of the equipment in the manner stated is not the subject of patent

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litigation, and that the manufacturer has not knowingly offered equipment which is likely to result in a patent controversy in which the City is likely to be made the defendant.

1.03 SUBMITTALS

A. Submit shop drawings to the City for all fabricated stainless-steel slide gates that include the following information:

1. Detailed custom drawings of the gate assembly with dimensional and mounting information. General arrangement drawings and cut sheets are not acceptable.

2. Materials list for all parts of the gate and gate appurtenances. These drawings shall include sufficient detail to determine if the proposed equipment meets the requirements specified herein and must include individual drawings for each typical gate to be provided.

3. Certification that submitted gates are in accordance with the latest edition of AWWA C561, except as modified herein.

4. Design calculations demonstrating anchor bolt sizing and spacing in compliance with AWWA C561.

5. Confirmation that the equipment, coatings, grease, and all other elements are ANSI/NSF 61 certified safe for use in drinking water applications.

6. Scaled drawings and diagrams of the manual operators.

7. Certification that the force required to operate all gates is as specified in Section 40 05 58 – Gate Operators and Electric Gate Actuators.

B. Submit to the City operation and maintenance manuals and installation instructions.

1. Include in each manual all pertinent instructions, as-built drawings as applicable, bills of materials, technical bulletins, installation and handling requirements, maintenance and repair instructions, and other information required for complete, accurate, and comprehensive data for safe and proper operation, maintenance, and repair of materials and equipment.

2. Submit complete, detailed written operating instructions including: function;

operating characteristics; limiting conditions; operating instructions for start-up, normal and emergency conditions; regulation and control; operational troubleshooting; and shutdown. Also include, as applicable, written descriptions of alarms generated by equipment and proper responses to such alarm conditions.

3. Submit written explanations of all safety considerations relating to operation and maintenance procedures.

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4. Submit complete, detailed, written preventive maintenance instructions including all information and instructions to keep materials, equipment, and systems properly lubricated, adjusted, and maintained so that materials, equipment, and systems function economically throughout their expected service life. Instructions shall include:

a. Written explanations with illustrations for each preventive maintenance task such as inspection, adjustment, lubrication, calibration, and cleaning. Include pre-startup checklists for each equipment item and maintenance requirements for long-term shutdowns.

b. Recommended schedule for each preventive maintenance task.

c. Lubrication charts indicating recommended types of lubricants, frequency of application or change, and where each lubricant is to be used or applied.

d. Table of alternative lubricants.

e. Troubleshooting instructions.

f. List of required maintenance tools and equipment.

5. Submit complete bills of material or parts lists for materials and equipment furnished. Lists or bills of material may be furnished on a per-drawing or per-equipment assembly basis. Bills of material shall indicate:

a. Manufacturer’s name, address, telephone number, fax number, and Internet website address.

b. Manufacturer’s local service representative’s or local parts supplier’s name, address, telephone number, fax number, Internet website address, and e-mail addresses, when applicable.

c. Manufacturer’s shop order and serial number(s) for materials, equipment or assembly furnished.

d. For each part or piece include the following information:

1) Parts cross-reference number. Cross-reference number shall be used to identify the part on assembly drawings, Shop Drawings, or other type of graphic illustration where the part is clearly shown or indicated.

2) Part name or description.

3) Manufacturer’s part number.

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4) Quantity of each part used in each assembly.

5) Current unit price of the part at the time the operations and maintenance manual is submitted. Price list shall be dated.

6. Submit complete instructions for ordering replaceable parts, including reference numbers (such as shop order number or serial number).

7. Submit manufacturer’s recommended inventory levels for spare parts, extra stock materials, and consumable supplies for the initial two years of operation.

Consumable supplies are items consumed or worn by operation of materials or equipment, and items used in maintaining the operation of material or equipment, including items such as lubricants, seals, reagents, and testing chemicals used for calibrating or operating the equipment. Include estimated delivery times, shelf life limitations, and special storage requirements.

8. Submit manufacturer’s installation and operation bulletins, diagrams, schematics, and equipment cutaways. Where materials pertain to multiple models or types, mark the literature to indicate specific material or equipment supplied. Marking may be in the form of checking, arrows, or underlining to indicate pertinent information, or by crossing out or other means of obliterating information that does not apply to the materials and equipment furnished.

9. Submit original-quality copies of each approved and accepted Shop Drawing, product data, and other submittal, updated to indicate as-installed condition.

Reduced drawings are acceptable only if reduction is to not less than one-half original size and all lines, dimensions, lettering, and text are completely legible on the reduction.

10. Submit complete electrical schematics and wiring diagrams, including complete point-to-point wiring and wiring numbers or colors between all terminal points.

11. Submit copy of warranty bond and service contract as applicable.

12. When copyrighted material is used in operations and maintenance manuals, obtain copyright holder’s written permission to use such material in the operation and maintenance manual.

C. Submittal procedure requirements:

1. On all submittals, provide a stamp of approval certifying submittal material has been reviewed and conforms to the Technical Specifications prior to submitted material for the City’s review.

2. Provide written notice of deviations or variations that a submittal may have with the Technical Specifications.

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3. Electronic submittals (PDF) are acceptable.

4. Revise and resubmit submittals until the City is satisfied that all review comments have been satisfactorily addressed.

5. The City’s review and acceptance of submittals shall not relieve the Company’s responsibility under the Contract to comply with the Technical Specifications. The City’s review is confined to general compliance with the Technical Specifications, and the omission of any review comment noting deviations or variation from the Technical Specifications shall not be construed as an acceptance by the City of such deviations or variations. The City shall consider only deviations and variations from the Technical Specifications provided in the manufacturer’s written notice (see Paragraph 1.03.C.2), and the City’s acceptance of deviations or variations shall only be given explicitly in writing.

PART 2 – PRODUCTS

2.01 GENERAL

A. Subject to compliance with the Specifications, equipment manufactures include Fontaine-Aquanox, Golden Harvest, Hydro Gate, Rodney Hunt, RW Gate Company, Waterman, Whipps, or approved equal. All fabricated stainless-steel slide gates shall be furnished by a single manufacturer.

B. The gates and appurtenances shall be designed for installation in the structures shown in the Figures.

C. As indicated in the schedule at the end of this specification section, gates shall be configured as self-contained or non-self-contained and shall be designed to surface mount directly to concrete (surface mounted or embedded) or to a wall bracket.

D. All gates are intended for submerged installation and shall be sealed on all 4 sides.

E. All gates shall be conventional closure.

F. Gate actuator shall be as identified in the schedule at the end of this specification section.

G. Stainless-steel nameplates shall be permanently attached to each pedestal (floor stand), yoke (bench), or torque tube (bench stand), indicating gate invert elevation, the Owner’s gate tag number, and the Manufacturer’s identification number. Coordinate with the City to receive installation-specific information to be included on the nameplates.

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H. Furnish all special tools necessary to operate, disassemble, service, repair, and adjust equipment and material in accordance with the manufacturer’s operation and maintenance manual.

2.02 FRAME AND GUIDES

A. The guides shall be integral with the frame. The frame assembly, including the guide members, invert member, and yoke member, shall be constructed of formed stainless steel plate with a minimum thickness of ¼-inch.

B. Flush-bottom closure type gates shall have a replaceable compressible resilient seal attached to the invert member of the frame. The seal shall be held in place with a retainer bar or molded into the frame invert. Designs that require the invert seal to be mounted on the slide shall not be allowed.

C. The guides shall be provided with holes for anchor bolts at a maximum spacing of 18-inches.

2.03 SLIDE

A. The slide (disc) shall be stainless-steel plate reinforced with structural shapes of the same alloy welded to the plate.

B. Slide deflection shall not exceed 1/720 of gate width at maximum design head, or 1/16 in., whichever is less.

2.04 ACTUATOR SUPPORT/MOUNTING

A. Self-contained gates shall be provided with a yoke machined to receive either a base-plate or torque tube for actuator mounting. The yoke shall be formed by two (2) angles or channels welded at the top of the guides to provide a one (1) piece rigid frame. The arrangement of the yoke shall be such that the stem and slide can be removed without disconnecting the yoke. At maximum operating load, yoke deflection shall not exceed 1/720 of gate width, or a maximum of ¼-inch, whichever is less.

B. Non-self-contained gates shall have a pedestal mounted to a reinforced concrete slab or wall-mounted bracket conservatively designed for the expected operating forces, and aligned with the gate stem.

2.05 STEMS AND STEM GUIDES

A. All gates shall be rising stem.

B. Operating stems shall be designed to transmit in compression at least 2-1/2 times the rated output of the operating mechanism with a 40-pound effort on the crank or handwheel.

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C. Stem design calculations shall use the stem minor diameter for calculating stem cross sectional area and stresses due to compression and tension loads.

D. Keys or pins shall be stainless steel materials matching the alloy of the gate stem. All threaded and keyed couplings of the same size shall be interchangeable.

E. Stem guides shall be adjustable in two directions and shall be placed according to Manufacturer’s recommendation, but in no case shall spacing exceed 10 feet on center.

In addition, stem slenderness ratio (l/r) shall not be greater than 200.

F. Rising stem gates shall be provided with an adjustable stop collar on the stem above and below the actuator lift nut. Collars below the nut shall not be required for self-contained gates where the frame height equals the gate height plus the range of travel of the slide.

2.06 SEALS

A. The seals shall be arranged to ensure that there is no metal-to-metal contact between the slide and frame.

B. Seals shall be mechanically fastened with stainless steel bolts. Invert seals attached by the use of adhesives are not acceptable.

C. All seats and seals shall be secured with assembly bolts. All seals shall be field removable and field replaceable without the need to remove the gate frame from the wall.

D. Anchor bolts shall not penetrate the seats or seals and anchor bolts shall not prevent the removal or replacement of seats or seals.

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2.07 MATERIALS

A. Materials for gates shall conform to the following specifications:

Frame Assembly Yoke, and Retainers Stainless Steel, Type 316L, ASTM A240

Slide and Stiffeners Stainless Steel, Type 316L, ASTM A240

Stem and Anchor Studs Stainless Steel, Type 316, ASTM A276

Stem Couplings and Stop Collars Stainless Steel, Type 316, ASTM A276 or Bronze, ASTM B584 (UNS C87200 or C87300)

Fasteners and Nuts Stainless Steel, Type 316, ASTM F593/F594 or ASTM A276

Invert Resilient Seal Neoprene or EPDM, ASTM D-2000

Gate Seat/Seals and Facing UHMW Polyethylene, ASTM D4020

Non-Rising Stem Thrust Nuts Bronze, ASTM B584 (UNS C87200 or C87300) or Bronze ASTM B505 (UNS C95800)

Actuator Lift Nuts Bronze, ASTM B584 (UNS C86300 or C86500) or Bronze ASTM B505 (UNS C95800)

Pedestal and Actuator Wall Brackets Stainless Steel, Type 316L, ASTM A276

Actuator Housing Cast Aluminum or Ductile Iron

Stem Guide Brackets Stainless Steel, Type 316L, ASTM A276

Stem Guide Bushings UHMW Polyethylene, ASTM D4020

PART 3 – EXECUTION

3.01 FACTORY TESTING

A. The manufacturer shall assemble and inspect each gate in the factory for proper seating.

Seals shall be adjusted to exclude a 0.004-inch thickness gauge between the seating surfaces.

B. Operate each gate from the fully open to the full closed position to verify the assembly functions as intended.

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C. Conduct factory testing with the job manual operators and satisfy the testing requirements included in Section 40 05 58 – Gate Operators and Electrical Gate Actuators.

D. The gates shall be tested in the factory for leakage and for operating force. Leakage shall be measured at the unseating design pressure. Operating force shall be measured with and without the design pressure. Factory test reports shall be available on request for all gates supplied.

E. No equipment shall be shipped to the project site until the City has been furnished with a certified copy of test results and a letter indicating that the results of such tests are acceptable.

F. Any equipment shipped to site that needs further attention shall have a WARNING tag affixed to it with indication of the action that should be taken in preparation for startup (e.g., Final Lubrication, etc.).

3.02 PAINTING

A. All ferrous parts, except stainless steel, of the gates and stem guides shall be blast-cleaned and painted with the manufacturer’s standard high-solids epoxy coating that is ANSI/NSF 61 certified safe for use in drinking water applications.

B. All machined iron surfaces, including drilled and tapped holes, shall be coated with a protective grease.

32220-039 40 05 59.23-10 WM1 VALVE & GATE ITB

FABRICATED STAINLESS STEEL SLIDE GATE SCHEDULE

Size Design Head ID No. Description Width

(in) Height

(in) Seating

(ft) Unseating

(ft)

Submerged / Free Surface

Open Direction

(Up/Down)

Gate Mount

Gate Configuration

Stem (Single/Dual)

Actuator Stand Mount

Actuator Type

FBI-201 Flocculator Basin 10 Influent 48 48 8 8 Submerged Up Concrete

Surface -Self-

Contained Single Yoke Mounted Hand-crank

FBI-202 Flocculator Basin 9 Influent 48 48 8 8 Submerged Up Concrete

Surface Self-

Contained Single Yoke Mounted Hand-crank

FBI-203 Flocculator Basin 8 Influent 48 48 8 8 Submerged Up Concrete

Surface Self-

Contained Single Yoke Mounted Hand-crank

FBI-204 Flocculator Basin 7 Influent 48 48 8 8 Submerged Up Concrete

Surface Self-

Contained Single Yoke Mounted Hand-crank

SBI-401 Sedimentation Basin 12 Influent 48 48 18 18 Submerged Up Concrete

Surface Non-Self- Contained Single Floorstand Hand-crank

SBI-402 Sedimentation Basin 12 Influent 48 48 18 18 Submerged Up Concrete

Surface Non-Self- Contained Single Floorstand Hand-crank

SBI-403 Sedimentation Basin 11 Influent 48 48 18 18 Submerged Up Concrete

Surface Non-Self- Contained Single Floorstand Hand-crank

SBI-404 Sedimentation Basin 11 Influent 48 48 18 18 Submerged Up Concrete

Surface Non-Self- Contained Single Floorstand Hand-crank

SBI-405 Sedimentation Basin 10 Influent 48 48 18 18 Submerged Up Concrete

Surface Non-Self- Contained Single Floorstand Hand-crank

SBI-406 Sedimentation Basin 10 Influent 48 48 18 18 Submerged Up Concrete

Surface Non-Self- Contained Single Floorstand Hand-crank

SBI-407 Sedimentation Basin 9 Influent 48 48 18 18 Submerged Up Concrete

Surface Non-Self- Contained Single Floorstand Hand-crank

SBI-408 Sedimentation Basin 9 Influent 48 48 18 18 Submerged Up Concrete

Surface Non-Self- Contained Single Floorstand Hand-crank

SBI-409 Sedimentation Basin 8 Influent 48 48 18 18 Submerged Up Concrete

Surface Non-Self- Contained Single Floorstand Hand-crank

SBI-410 Sedimentation Basin 8 Influent 48 48 18 18 Submerged Up Concrete

Surface Non-Self- Contained Single Floorstand Hand-crank

SBI-411 Sedimentation Basin 7 Influent 48 48 18 18 Submerged Up Concrete

Surface Non-Self- Contained Single Floorstand Hand-crank

SBI-412 Sedimentation Basin 7 Influent 48 48 18 18 Submerged Up Concrete

Surface Non-Self- Contained Single Floorstand Hand-crank

32220-039 40 05 64-1 WM1 VALVE & GATE ITB

SECTION 40 05 64

RECTANGULAR BUTTERFLY VALVES

PART 1 – GENERAL

1.01 THE REQUIREMENT

A. Furnish and deliver all valves complete with all accessories, spare parts, mountings, anchor bolts and other appurtenances as specified herein and as required for a complete and operating installation.

B. Refer to the schedule at the end of this specification section for further detail on valve location, dimensions, design criteria, number required, etc.

C. Manual and electric valve actuators (operators) shall be as specified in Section 40 05 57 Valves Operators and Electric Valve Actuators.

D. In this specification section, the term “manufacturer” refers to the entity manufacturing the rectangular butterfly valves.

1.02 WARRANTY

A. Equipment and material, including the actuators (manual and electric) shall be guaranteed to be free from defects in workmanship, design, and/or materials for a period of two (2) years.

B. Warranty period shall start on the date that the particular equipment and material is installed and successfully completes field testing by others or one hundred eighty (180) days after delivery, whichever is earlier.

C. Within the warranty period, the manufacturer shall repair or replace any component which is defective or showing undue wear, or replace the entire valve with a new unit if the mechanical performance is unsatisfactory. When performing such remediation, the Company shall furnish all parts, materials, labor, etc. and bear 100% of the costs to do so for at least the first year of the warranty period. These repair/replacement costs may be linearly prorated for the second year of the warranty period.

D. The Company shall guarantee to the City that all equipment offered, or that any process resulting from the use of the equipment in the manner stated is not the subject of patent litigation, and that the manufacturer has not knowingly offered equipment which is likely to result in a patent controversy in which the City is likely to be made the defendant.

1.03 SUBMITTALS

A. Submit shop drawings for all valves to the City to demonstrate full compliance with the specifications and ensure equipment will fit and operate in the space available. The shop drawings shall include the following information at minimum:

01-23-20 11-02-21

32220-039 40 05 64-2 WM1 VALVE & GATE ITB

1. Detailed custom drawings of the valve assembly with dimensional and mounting information. General arrangement drawings and cut sheets are not acceptable.

2. Materials list for all parts of the valve and valve appurtenances. These drawings shall include sufficient detail to determine if the proposed equipment meets the requirements specified herein and must include individual drawings for each typical gate to be provided.

3. Confirmation that the equipment, coatings, grease, and all other elements are ANSI/NSF 61 certified safe for use in drinking water applications.

4. Scaled drawings of the manual operators and electric actuators.

5. For electrically operated/controlled valves, provide details, notes, and diagrams which clearly identify required coordination with electrical power supply and remote status and alarm indicating devices. Include electrical control schematic diagrams drawing using a ladder-type format in accordance with JIC standards.

6. Certification that the force required to operate all valves is as specified in Section 40 05 57 – Valve Operators and Electric Valve Actuators.

7. Detailed storage and installation instructions for each valve type.

B. Submit to the City operation and maintenance manuals and installation instructions.

1. Include in each manual all pertinent instructions, as-built drawings as applicable, bills of materials, technical bulletins, installation and handling requirements, maintenance and repair instructions, and other information required for complete, accurate, and comprehensive data for safe and proper operation, maintenance, and repair of materials and equipment.

2. Submit complete, detailed written operating instructions including: function;

operating characteristics; limiting conditions; operating instructions for start-up, normal and emergency conditions; regulation and control; operational troubleshooting; and shutdown. Also include, as applicable, written descriptions of alarms generated by equipment and proper responses to such alarm conditions.

3. Submit written explanations of all safety considerations relating to operation and maintenance procedures.

4. Submit complete, detailed, written preventive maintenance instructions including all information and instructions to keep materials, equipment, and systems properly lubricated, adjusted, and maintained so that materials, equipment, and systems function economically throughout their expected service life. Instructions shall include:

a. Written explanations with illustrations for each preventive maintenance task such as inspection, adjustment, lubrication, calibration, and cleaning. Include

32220-039 40 05 64-3 WM1 VALVE & GATE ITB

pre-startup checklists for each equipment item and maintenance requirements for long-term shutdowns.

b. Recommended schedule for each preventive maintenance task.

c. Lubrication charts indicating recommended types of lubricants, frequency of application or change, and where each lubricant is to be used or applied.

d. Table of alternative lubricants.

e. Troubleshooting instructions.

f. List of required maintenance tools and equipment.

5. Submit complete bills of material or parts lists for materials and equipment furnished. Lists or bills of material may be furnished on a per-drawing or per-equipment assembly basis. Bills of material shall indicate:

a. Manufacturer’s name, address, telephone number, fax number, and Internet website address.

b. Manufacturer’s local service representative’s or local parts supplier’s name, address, telephone number, fax number, Internet website address, and e-mail addresses, when applicable.

c. Manufacturer’s shop order and serial number(s) for materials, equipment or assembly furnished.

d. For each part or piece include the following information:

1) Parts cross-reference number. Cross-reference number shall be used to identify the part on assembly drawings, Shop Drawings, or other type of graphic illustration where the part is clearly shown or indicated.

2) Part name or description.

3) Manufacturer’s part number.

4) Quantity of each part used in each assembly.

6. Submit complete instructions for ordering replaceable parts, including reference numbers (such as shop order number or serial number).

7. Submit manufacturer’s recommended inventory levels for spare parts, extra stock materials, and consumable supplies for the initial two years of operation.

Consumable supplies are items consumed or worn by operation of materials or equipment, and items used in maintaining the operation of material or equipment, including items such as lubricants, seals, reagents, and testing chemicals used for

32220-039 40 05 64-4 WM1 VALVE & GATE ITB

calibrating or operating the equipment. Include estimated delivery times, shelf life limitations, and special storage requirements.

8. Submit manufacturer’s installation and operation bulletins, diagrams, schematics, and equipment cutaways. Where materials pertain to multiple models or types, mark the literature to indicate specific material or equipment supplied. Marking may be in the form of checking, arrows, or underlining to indicate pertinent information, or by crossing out or other means of obliterating information that does not apply to the materials and equipment furnished.

9. Submit original-quality copies of each approved and accepted Shop Drawing, product data, and other submittal, updated to indicate as-installed condition.

Reduced drawings are acceptable only if reduction is to not less than one-half original size and all lines, dimensions, lettering, and text are completely legible on the reduction.

10. Submit complete electrical schematics and wiring diagrams, including complete point-to-point wiring and wiring numbers or colors between all terminal points.

11. Submit copy of warranty bond and service contract as applicable.

12. When copyrighted material is used in operations and maintenance manuals, obtain copyright holder’s written permission to use such material in the operation and maintenance manual.

C. Submittal procedure requirements:

1. On all submittals, provide a stamp of approval certifying submittal material has been reviewed and conforms to the Technical Specifications prior to submitted material for the City’s review.

2. Provide written notice of deviations or variations that a submittal may have with the Technical Specifications.

3. Electronic submittals (PDF) are acceptable.

4. Revise and resubmit submittals until the City is satisfied that all review comments have been satisfactorily addressed.

5. The City’s review and acceptance of submittals shall not relieve the Company’s responsibility under the Contract to comply with the Technical Specifications. The City’s review is confined to general compliance with the Technical Specifications, and the omission of any review comment noting deviations or variation from the Technical Specifications shall not be construed as an acceptance by the City of such deviations or variations. The City shall consider only deviations and variations from the Technical Specifications provided in the manufacturer’s written notice (see Paragraph 1.03.C.2), and the City’s acceptance of deviations or variations shall only be given explicitly in writing.

32220-039 40 05 64-5 WM1 VALVE & GATE ITB

PART 2 – PRODUCTS

2.01 RECTANGULAR BUTTERFLY VALVES

A. Rectangular butterfly valves shall be bubble tight with flow in either direction.

Rectangular butterfly valves shall be manufactured by Pratt, Hydro Gate, or equal. The valve body shall be fabricated carbon steel, designed for thimble mounting. The manufacturer shall configure bolt holes on the body assembly to match that of the existing thimbles to which the valves will be affixed. The valve disc shall be fabricated of carbon steel with Type 304 stainless steel seating edge. The disc shall be streamlined in shape to prevent turbulence in fully open position and to minimize pressure drop across valve. The valve seat, contained in the body of the valve, shall be a synthetic rubber compound with a durometer of 60.

B. Seat adjustment shall not be less than 1/8 inch. Valve seat shall be fully field adjustable and replaceable without dismantling operator, disc, or shaft and without the use of special tools. Valve shaft shall be 304 stainless steel securely locked to disc by stainless steel taper pins.

C. Each valve assembly shall be furnished with a 2-way thrust bearing assembly designed to hold the disc centered in the seat at all times. Thrust bearing shall be secured by locking device and easily accessible for field adjustment from operator end of valve.

D. Valve operators shall conform to AWWA-C504 and shall be designed to hold the valve in any intermediate position between fully closed and fully open without creeping or fluttering. Manual operators shall be of the travelling nut, self-locking type and shall be equipped with mechanical stop-limiting devices to prevent over travel of the disc.

Operators shall be fully enclosed and designed to produce the specified torque with a maximum pull of 80 lb. on the handwheel.

E. All internal and external ferrous components and surfaces of the valves, with the exception of stainless steel and finished or bearing surfaces, shall be shop painted with two coats (10 mils min.