Atch 1 - Isolation_Relief Valve Specifications.pdf

NOT SENSITIVE IRA-3919

Isolation and Relief Valves for NGTETC

Description: This purchase request is for the isolation valves and relief valves associated with the

NGTETC project at Arnold Engineering Development Complex. The items will be as summarized:

- HPA-MV1-RF: (1) 3” Schedule 160 Class 2500 RTJ Ball Valve. Body material shall be 304/316

Stainless Steel. Valve will be motor operated (480 V/60 Hz/3 Phase).The medium for this valve will be air with a design pressure of 4400 psig and a design temperature between -20 and 110

°F. (See detail sheet below for complete details)

- HPA-V24-RF: (1) 3” Schedule 160 Class 2500 RTJ Ball Valve. Body material shall be 304/316

Stainless Steel. This valve will be manually operated with a hand wheel. The medium for this valve will be air with a design pressure of 4400 psig and a design temperature between -20 and

110 °F. (See detail sheet below for complete details)

- HPA-RV3-RF: (1) 3” x 4” x 4” (dual outlet) Class 600/150 RF High Pressure Air Relief Valve. Body material shall be 304/316 Stainless Steel. Pilot Operated (Modulating). (See detail sheet below for complete details)

- Motor Actuated 8-inch NPS Class 2500 Gate Valve Assembly: Complete Specification attached below (Pages 5-20)

ISOLATION VALVE DATA SHEET 14327-HPA-MV1-RF

Identity

DESCRIPTION AND TAG NO.: HPA-MV1-RF SCHEMATIC NO.:

SPECIFICATION NO.: N/A DESIGN CODE: ASME B16.34

PIPE DESIGN: ASME B31.3 DATA TABLE: N/A

Operating Conditions

MEDIUM: ☒ Air SERVICE CONDITION: ☒ On-Off

MAXIMUM ALLOWABLES:

a) Shutoff Pressure Differential: 4400 psig

SPECIFIC GRAVITY: 1.00 b) Temperature: -20 to 110 °F

MINIMUM Cv: c) Occur Simultaneously: ☒ Yes

DESIGN TEMPERATURE: -20 to 110 °F FLUID VELOCITY AT VALVE INLET: 52 fps

DESIGN PRESSURE: 4400 psig PRESSURE LOSS WHEN FULLY OPEN: 4400 psig

ENVIRONMENT: ☒Outdoor NOTES:

Valve Specifications

BODY TYPE: ☒ Ball TRIM MATERIAL: ☒ 304 Stainless Steel

BODY RATING (ANSI): ☒ Class 2500 END CONNECTION TYPE, SIZE, & SCHEDULE:

a) Inlet: ☒ Flanged

NPS: 3 Schedule: 160 Flange Type : RTJ

BODY MATERIAL:

a) ☒ 304 Stainless Steel or ☒ 316 Stainless Steel b) Outlet: ☒ Flanged

NPS: 3 Schedule: 160 Flange Type: RTJ

STUFFING BOX PACKING: ☒ Single

SEAT MATERIAL: NOTES:

☒ Metal

Actuator Specifications

ACTUATOR TYPE: ☒ Motor LIMIT SWITCHES: ☒ None

LIMIT SWITCH LOCATIONS:

MAXIMUM RIM PULL: 40 lbf

ACCESSORIES: LIMIT SWITCH TYPES/CLASS: SPDT / Form C

☒ Auxiliary Hand wheel SOLENOID OPERATOR:

ACTUATOR MOTOR: ☒ Yes SOLENOID LOCATION:

Volt: 480 V No. of Phases: 3 Frequency: 60 Hz HYDRAULIC SERVO:

ENCLOSURE: HYDRAULIC SERVO LOCATION:

☒ Completely Sealed STARTS:

☒ Internal Mechanically ☒ Electrically Interlocked

Testing

Testing shall be in accordance with the following:

1. Hydrostatic Pressure Test per ASME B16.34

2. Valve Testing per MSS SP-61

3. Seat Leakage Test per MSS SP-61

Submittals

The following submittals are required:

1. Valve Drawing

2. Shop Test Reports

3. Certified Material Test Report

4. Manual that includes specification sheets for all components of valve assembly

Remarks

1. Design Valve as Full Port Valve.

2. Valve, actuator, and listed accessories furnished assembled as a single unit

3. Furnish with an integral 1 inch bypass valve (per vendor preferred valve body type)

4. HPA-MV1-RF and HPA-V24-RF shall have identical valve bodies with different actuators as specified

5. Full assembly must be lockable with a standard key lock

6. Flanges on valves shall have clearance through holes. Tapped holes are not permitted.

ISOLATION VALVE DATA SHEET 14327-HPA-V24-RF

DESCRIPTION AND TAG NO.: HPA-V24-RF SCHEMATIC NO.:

SPECIFICATION NO.: N/A DESIGN CODE: ASME B16.34

PIPE DESIGN: ASME B31.3 DATA TABLE: N/A

Operating Conditions

MEDIUM: ☒ Air SERVICE CONDITION: ☒ On-Off

MAXIMUM ALLOWABLES:

a) Shutoff Pressure Differential: 4400 psig

SPECIFIC GRAVITY: 1.00 b) Temperature: -20 to 110 °F

MINIMUM Cv: c) Occur Simultaneously: ☒ Yes

DESIGN TEMPERATURE: -20 to 110 °F FLUID VELOCITY AT VALVE INLET: 52 fps

DESIGN PRESSURE: 4400 psig PRESSURE LOSS WHEN FULLY OPEN: 4400 psig

ENVIRONMENT: ☒Outdoor NOTES:

Valve Specifications

BODY TYPE: ☒ Ball TRIM MATERIAL: ☒ 304 Stainless Steel

BODY RATING (ANSI): ☒ Class 2500 END CONNECTION TYPE, SIZE, & SCHEDULE:

a) Inlet: ☒ Flanged

NPS: 3 Schedule: 160 Flange Type: RTJ

BODY MATERIAL:

a) ☒ 304 Stainless Steel or ☒ 316 Stainless Steel b) Outlet: ☒ Flanged

NPS: 3 Schedule: 160 Flange Type: RTJ

STUFFING BOX PACKING: ☒ Single

SEAT MATERIAL: NOTES:

☒ Metal

Actuator Specifications

ACTUATOR TYPE: LIMIT SWITCHES: ☒ None

☒ Hand wheel LIMIT SWITCH LOCATIONS:

MAXIMUM RIM PULL: 40 lbf

ACCESSORIES: LIMIT SWITCH TYPES/CLASS: SPDT / Form C

SOLENOID OPERATOR:

ACTUATOR MOTOR: ☒ No SOLENOID LOCATION:

Volt: 480 V No. of Phases: 3 Frequency: 60 Hz HYDRAULIC SERVO:

ENCLOSURE: HYDRAULIC SERVO LOCATION:

STARTS:

Testing

Testing shall be in accordance with the following:

1. Hydrostatic Pressure Test per ASME B16.34

2. Valve Testing per MSS SP-61

3. Seat Leakage Test per MSS SP-61

1. Valve Drawing

2. Shop Test Reports

4. Manual that include specification sheets for all components of valve assembly

1. Design Valve as Full Port Valve.

2. Valve, actuator, and listed accessories furnished assembled as a single unit

3. HPA-MV1-RF and HPA-V24-RF shall have identical valve bodies with different actuators as specified

4. Full assembly must be lockable with a standard key lock

5. Flanges on valves shall have clearance through holes. Tapped holes are not permitted.

RELIEF VALVE DATA SHEET 14327-HPA-RV3-RF

DESCRIPTION AND TAG NO.: High Pressure Air Relief Valve SCHEMATIC NO.:

SPECIFICATION NO.: N/A DESIGN CODE: ASME Section VIII DIV 1

PIPE DESIGN: ASME B31.3 DATA TABLE: N/A

Operating Conditions

MEDIUM: ☒ Air TOTAL BACKPRESSURE: 0 psig

FLOW RATE: 15 ☒Lb/sec

DESIGN TEMPERATURE: -50 to 110 °F

SPECIFIC GRAVITY: .104 (based on 1353 psig and 110 °F) DESIGN PRESSURE: 1230 psig

COMPRESSIBILITY FACTOR: 1.0 SET PRESSURE: 1353 psig – see Remarks below

OPERATING TEMPERATURE: -50 to 110 °F ACCUMULATION: ☒10%

OPERATING PRESSURE: 1105 psig BLOWDOWN : ☒ Vendor Standard

SUPERIMPOSED BACKPRESSURE: psig ENVIRONMENT: ☒Outdoor

BUILTUP BACKPRESSURE: psig NOTES:

Valve Specifications

VALVE TYPE: END CONNECTION TYPE:

a) ☒ Safety a) Inlet: ☒ Flanged

b) ☒ Pilot Operated NPS: 3” Class: 600# Flange Type: RF c)

NOZZLE TYPE: b) Outlet: ☒ Flanged

☒ Per Vendor NPS: 4” x 4 ” Dual Outlet Class: 150# Flange Type: RF

SIZING BASIS: ☒ Code

BODY MATERIAL: CONNECTION SIZE & CLASS:

a) ☒ 304 Stainless Steel or ☒ 316 Stainless Steel Inlet: NPS: Class: Flange Type:

Outlet: NPS: Class: Flange Type:

WELD END:

MINIMUM ORIFICE AREA: ☒ Per Vendor

TRIM MATERIAL: SELECTED ORIFICE: Full Bore

☒ Metal (Specify): 300 series stainless steel ☒ Per Vendor

CAP: ☒ Per Vendor

SEAT MATERIAL: LEVER: ☒ Plain

☒ Per Vendor TEST GAG: ☒ No

NOTES:

Actuator Specifications

PILOT ACTION: ☒ Modulating PILOT INLET FILTER: ☒ Yes

FIELD TEST CONNECTION: ☒ Yes PILOT INLET SNUBBER: ☒ No

NOTES: BACK FLOW PREVENTER: ☒ No

Testing

Testing shall be in accordance with the following:

1. Hydrostatic Pressure Test per ASME Section VIII

1. Valve Drawing

2. Valve Datasheet

1. Valve, actuator, and listed accessories furnished assembled as a single unit

2. Valve shall be capable of being re-set for design pressure of 800 psig relief service

14327-21-001

SPEC NO. 14327-21-001

18 June 2021

EQUIPMENT SPECIFICATION

FOR

MOTOR ACTUATED 8-INCH NPS CLASS 2500 GATE VALVE ASSEMBLY

ARNOLD ENGINEERING DEVELOPMENT COMPLEX

ARNOLD AIR FORCE BASE, TN 37389-9998

DISTRIBUTION STATEMENT A

Approved for Public Release

Distribution Unlimited

IRA-3919

Approved for Public Release: Distribution Unlimited

IRA-3919 Table of Contents-1

TABLE OF CONTENTS

1. Scope

2. Applicable Documents

2.1. Government Documents

2.2. Non-Government Documents

3. Requirements

3.1. General

3.2. Valve Requirements

3.3. Electric Motor Actuator Requirements

3.4. Controls and Instrumentation Requirements

3.5. Submittal Summary table

4. Verification

4.1. Engineering Analysis

4.2. Testing

4.3. Cleaning and Drying

4.4. Actuator Testing

4.5. Acceptance

5. Packaging

5.1. Preparation for Delivery

5.2. Post-Delivery Storage

6. Notes Appendix A – 1 Valve Data Sheet

IRA-3919 Page-1

1. SCOPE

Contractor shall supply one 8-Inch NPS class 2500 gate valve assembly. The valve assembly shall consist of a full ported, parallel slide type gate valve supplied with butt weld ends, bypass valve and piping, electric motor actuator, motor starter, internal position feedback transmitters, and related mounting hardware. Valve shall be delivered to Arnold AFB, TN.

2. APPLICABLE DOCUMENTS

2.1. Government Documents: None.

2.2. Non-Government Documents.

2.2.1 American Society of Mechanical Engineers (ASME):

A. ASME B16.34-20 Valves – Flanged, Threaded, and Welding End.

B. ASME B16.10-17 Face to Face and End to End Dimensions of Valves.

C. ASME SEC VIII-20 Boiler and Pressure Vessel Code.

2.2.2 American Society for Testing and Materials (ASTM):

A. ASTM A182-21 Standard Specification for Forged or Rolled Alloy and Stainless Steel Pipe Flanges, Forges Fittings, and Valves and Parts for High-Temperature Service.

B. ASTM B117-19 Standard Practice for Operating Salt Spray (Fog) Apparatus.

2.2.3 Manufacturer’s Standardization Standard (MSS):

A. MSS SP-45-20 Drain and Bypass Connections

B. MSS SP-55-11 Quality Standard for Steel Castings for Valves.

C. MSS SP-61-19 Pressure Testing of Valves.

2.2.4 National Fire Protection Association (NFPA):

A. NFPA 70-20 National Electric code (NEC).

2.2.5 Underwriters Laboratories, Inc.:

IRA-3919 Page-2

A. UL Electrical Appliance-12 Electrical Appliance and Utilization Equipment Directory.

3. REQUIREMENTS

3.1. General: Valve assembly, comprised of valve, electric motor actuator, motor starter, by-pass valve and piping, internal position feedback transmitters, and related components, shall be designed, fabricated, assembled, tested and supplied in accordance with Section 2, Applicable Documents, Appendix A – Valve Data Sheet, and as follows:

3.1.1 Service:

A. Valve assembly shall be used for isolation (flow / no flow) of 1230 psig air at -50 to 1250 degrees F.

B. The valve assembly shall be rated for the design conditions listed in Appendix A – Valve Data Sheet.

3.1.2 Corrosion Protection: All external exposed carbon steel or iron surfaces shall be primed and painted per manufacturer’s standard practice for outside service to preclude rust and corrosion.

3.1.3 Human Factors Engineering:

A. All moving parts shall be fully enclosed or properly guarded to prevent contact with personnel.

B. Components requiring adjustment, maintenance, or calibration shall be accessible with valve in service.

C. Valve assembly shall not contain any lead or asbestos.

3.1.4 Workmanship:

A. All components of the valve assembly shall be constructed and finished in such a manner that no sharp edges, burrs, or physical defects are present.

B. Welds of the interior of the valve shall be ground smooth and all slag removed. The surfaces shall be free from oxide, slag, scale, loose debris, dirt, rust, and other foreign matter and harmful contaminants.

3.1.5 Reliability:

A. Duty Cycle: The duty cycle for the valve assembly shall be designed for 200 cycles/year. A cycle consists of moving the valve from closed to open

IRA-3919 Page-3 to closed at the maximum operating pressure and minimum and maximum operating temperature.

B. Valve assembly shall be designed for not less than a 25-year life with mean time between failures (MTBF) of not less than 2000 operational cycles.

C. Valve shall maintain leakage rate as defined in Appendix A – Valve Data Sheet after 2000 cycles.

D. Valve assembly shall be capable of operation after a 6-month period of inactivity without requiring any maintenance or repairs.

E. Actuator shall be designed for operational life of 1 million sleeve turns.

3.1.6 Maintainability: Valve assembly shall be designed for a mean time to repair (MTTR) not greater than 32 hours for the valve and related components. Any special tooling required to maintain shall be provided with the valve assembly.

3.1.7 Transportability:

A. Valve assembly shall be constructed to allow installation and removal as one unit.

B. Permanent lug(s) shall be provided for lifting valve assembly at the center of gravity (cg) in its installation orientation by crane. Clearly mark lifting points and loads.

3.1.8 Nameplates and Markings:

A. Each major component of equipment shall have the manufacturer's name, address, type or style, model or serial number, catalog number, pressure class and flow capacity (CV) on a plate secured to the equipment.

B. Primary flow direction markings shall be prominently and permanently displayed on the valve indicating flow direction.

C. Electrical components listed in UL Electrical Appliance shall have UL label or registration plate secured to the component.

3.2. Valve Requirements: Valve shall be in accordance with Appendix A – Valve Data Sheet and as follows:

3.2.1 Valve Body and Bonnet:

A. Body material shall be suitable for the listed operating conditions and shall be submitted to the Government for approval.

B. Body shall be provided with insulation blankets.

IRA-3919 Page-4

C. Bonnet shall be pressure seal style.

D. The body joint bolted connection shall be designed to meet and exceed ASME Section VIII, Div 1, Appendix 2 criteria.

3.2.2 Valve Disc:

A. Disc material shall be suitable for the listed operating conditions and shall be submitted to the Government for approval.

B. Disc sealing surfaces shall be hard faced.

C. Disc shall be parallel slide style.

3.2.3 Valve Seat:

A. Valve seat material shall be suitable for the listed operating conditions and shall be submitted to the Government for approval.

B. Valve seat shall be hard faced.

3.2.4 Valve Shaft:

A. Shaft material shall be suitable for the listed operating conditions and shall be submitted to the Government for approval.

3.2.5 Valve Packing and Packing Glands:

A. Packing shall be non-asbestos with a thermal rating as required in Appendix A - Valve Data Sheet.

B. Packing shall be live loaded to minimize leakage due to thermal expansion.

C. Packing glands shall be capable of being repacked externally without disassembly of any part of the valve other than the gland itself.

D. With valve open, packing shall be protected from operating conditions by a backseat.

3.2.6 Bypass Valve and Piping:

A. Bypass valve and piping shall be integral to the 8” valve body.

B. Bypass valve shall be motor operated.

C. Bypass valve and piping shall be of welded construction.

IRA-3919 Page-5

D. Bypass valve shall be 1-1/2 NPS per MSS SP-45 paragraph 4.1.

E. Bypass valve shall have a manual override.

F. Bypass valve type to be as recommended by manufacturer.

G. Connections of bypass piping to 8” valve body shall be at locations A and B per ASME B16.34 paragraph 6.3.7.

3.3. Electric Motor Actuator Requirements: Electric motor actuator shall be in accordance with Appendix A – Valve Data Sheet, NFPA 70, and as follows:

3.3.1 Electric motor actuator design (motor size and actuator gearing) shall be fully coordinated with valve design so that the stall torque of the electric motor actuator cannot damage the valve and actuator drive train.

3.3.2 Design electric motor actuator so that it can be removed without removal of the valve from the piping system.

3.3.3 Electric motor actuator package shall be contained in a weatherproof enclosure suitable for operation in an unsheltered outdoor environment.

3.3.4 Electric motor shall be specifically designed for valve actuator service and shall be of high starting torque, totally enclosed in accordance with NEMA 4, non-ventilated construction.

A. Motor insulation shall be a minimum NEMA Class F with a maximum continuous temperature rating of 155 degrees C (rise plus ambient) for the duty cycle specified.

B. Motor shall be of sufficient size to open and close the valve at the maximum torque. Motor shall be capable of complete operation at plus or minus 10 percent of specified voltage. Motor duty rating shall be sufficient for two complete cycles (open-close-open, or close-open-close) in immediate succession without exceeding its temperature rating.

C. Motor bearings shall be of the antifriction type and permanently lubricated.

D. Motor shall be an independent removable subassembly to allow for motor or gear or ratio changes dictated by system operation requirements.

E. Motor shall be equipped with internal thermal sensors embedded in the windings to protect against motor overload.

F. Motor shall be provided with thermal overload protection and an internal 1-phase, 60 Hz, 120 Volt space heater with thermostat.

G. Actuator electrical compartment shall be provided with an internal 1-phase, 60 Hz, 120 Volt space heater with thermostat.

IRA-3919 Page-6

H. The motor actuator shall be 480VAC, 60Hz, 3 phase. Power shall be supplied by the Government. The control power shall be 120 VAC, 60Hz, 1 phase and shall be furnished from an integral motor starter control power transformer.

3.3.5 Actuator shall be a single or multiple reduction unit with power gearing consisting of spur, helical or bevel gears and/or worm gearing. Valve shall be protected from maximum torque from motor/gear box exceeding valve/shaft design limits.

A. Spur, helical, or bevel gearing and worm shall be of hardened alloy steel, and the worm gear shall be alloy bronze.

B. Do not use nonmetallic, aluminum or cast gearing.

C. All gears and shafting shall be supported on anti-friction bearings. Where thrust is a consideration, tapered roller bearings shall be provided to accept thrust.

D. Actuator shall have a removable stem nut or drive bushing of high tensile bronze or other material compatible with the valve stem material.

E. All rotating drive train components shall be immersed in grease or oil with provisions for inspection and lubrication without disassembly.

F. Seals shall be provided at all exit points of the gear case to prevent leakage of lubricant. Critical areas subject to high wear shall be double sealed.

G. All lubricants shall be suitable for service conditions.

H. Provide mechanical valve position indicator showing the valve position from closed to open in percent. The pointer of the position indicator shall be clearly visible.

I. Provide a mechanical means of locking the valve in the full open and full closed positions with an external key lock.

J. Provide a metallic hand wheel for manual operation with an arrow and the word "open" to indicate open rotation direction. Hand wheel shall operate in the clockwise direction to close. Hand wheel shall not rotate during motor operation and operation by hand wheel shall not cause the motor to rotate. Hand wheel shall be capable of manual operation regardless of the status of power to the motor. When in the manual operating mode, actuator shall remain in this mode until the motor is energized, at which time the actuator shall automatically return to electric operation. Hand wheel shall require an effort of no more than 80 pounds on the rim for seating or unseating load, and 60 pounds for running load. Movement from motor operation to hand wheel operation shall be accomplished by a

IRA-3919 Page-7 positive declutch lever which mechanically disengages the motor and related gearing. Actuator shall be designed such that manual and motor operation cannot occur simultaneously. Do not use friction type declutch mechanism.

K. An electronic torque sensor shall be included. The torque limit shall be externally adjustable. The motor shall be de-energized if the torque limit is exceeded. A boost function shall be included to prevent torque trip during the initial valve unseating. A “Jammed Valve” protection feature, with automatic retry sequence shall be incorporated to de-energize the motor if no movement occurs.

L. Provide internally adjustable limit switches at open and closed positions.

Switches shall be field adjustable, allowing for trip points from fully open to fully closed positions or any intermediate point of valve travel. Switches shall not be subject to breakage or slippage due to over-travel. Limit switch design shall permit visual verification of switch position without disassembly. Limits shall not be a gearing type limit, must be an electrical feedback limit.

3.3.6 The actuator shall be furnished with a terminal strip, mounted inside the actuator, for field wiring termination to accommodate the wiring between the integral motor starter and the motor starter remote controls. The equipment shall be installed inside the actuator and shall be wired to the internal terminal strip. The equipment includes the following:

A. Actuator Motor.

B. 120 VAC Space Heater with Thermostat.

C. 120 VAC Motor Heater.

D. Torque Switches.

E. Potentiometer.

F. Limit Switch Sets.

3.3.7 A phase correction circuit shall be included to correct motor rotation faults caused by incorrect site wiring. The phase correction circuit shall also detect the loss of a phase and disable operation to prevent motor damage. The monitor relay shall trip and an error message shall be displayed on the LCD screen when loss of phase occurs and indicate the fault for remote operation.

3.3.8 Discrete remote control shall be configured as two, three, or four wire for open-stop-close control. Remote control functions shall be powered by external 24VDC, 125 VAC, or the actuator’s internal 24 VDC supply.

IRA-3919 Page-8

3.3.9 Terminals shall be included to connect the electronic controls package, including display, to a backup 24 VDC power source. As a standard alternative, the actuator shall have the ability to maintain the status and alarm contacts in order to update status to the control room and also provides status visibility on the LCD screen without main power applied. It shall be configurable for at least one hour and, once main power is restored, be available for the next unforeseen power outage. The electronics do not require battery backup.

3.3.10 Four latched status contacts rated 125 VAC, 0.5 A and 30 VDC, 2 A shall be provided for remote indication of valve position, configured as 1-N/O and 1-N/C for both the open and closed positions. Four additional two contacts shall be configured to represent any other actuator status; mid-travel position, switched to local, over torque, motor over temperature, manual operation, switched to remote, switched to stop, valve moving, close torque switch, open torque switch, hardware failure, ESD active, inhibits active, valve jammed, analog IP (input) lost, lost phase, and network controlled.

3.3.11 A pad lockable LOCAL-STOP- REMOTE switch and an OPEN-CLOSE switch shall be included for local valve actuator control. The control switches shall not penetrate the controls cover and shall be designed to electrically isolate the actuator’s internal components from the external environment. The OPEN- CLOSE switch shall be configured for maintained or push-to-run (inching) control.

3.3.12 The actuator shall be non-intrusive. All calibration shall be possible without removing any covers and without the use of any special tools. All calibration shall be performed in clear text languages; no icons shall be used. A configurable password option shall be available to prevent unauthorized changes.

3.3.13 Double sealed terminal compartment and terminal block - All customer connections shall be located in a terminal chamber that is separately sealed from all other actuator components. Site wiring shall not expose actuator components to the environment. The internal sealing within the terminal chamber is suitable for NEMA 4. The chamber shall include screw-type terminals, three for power and a minimum of 20 for control, for site connections. Two ¾” NPT conduit entries shall be provided.

3.3.14 Coatings - The actuator shall be coated. The coating system shall be suitable for an ASTM B117 salt spray test of 1500 hours. External fasteners shall be stainless steel or high-strength carbon steel that has been coated suitable for an ASTM B117 salt spray test of 500 hours.

3.3.15 Diagnostic facilities shall be included to accumulate and report the performance of the motor, encoder, contactor, cycle time, hand-wheel operations, actuator ID, firmware revision, and output turns. In addition, a torque profile of the reference baseline valve stroke and the last valve stroke shall be included. A feature for reset shall be provided. All diagnostic information shall be displayed on the LCD.

IRA-3919 Page-9

3.3.16 The contractor shall submit valve actuator and valve motor data sheets within two weeks of notice of award.

3.4. Controls and Instrumentation Requirements:

3.4.1 Valve position shall be sensed by an optical, absolute positon encoder with redundant position sensing circuits designed for self-test. Each of the position sensing circuits shall be redundant permitting up to 50% fault tolerance before the position is incorrectly reported. The feature shall discern which failures signal a warning only and which require a warning plus safe shutdown of the actuator.

Open and closed positions shall be stored in permanent, nonvolatile memory.

The encoder shall measure valve positon at all times, including both motor and hand wheel operation, with or without power present, and without the use of a battery.

A. Feedback transducer input voltage: +9 to +28.8 VDC.

B. Provide an analog current output: 4 to 20 mA.

3.4.2 The control module shall include power and logic circuit boards, control transformer, and at least two primary power protection fuses, all mounted to a steel plate and attached in the control compartment with captive screws. The module shall be easily removed through the use of plug-in connectors. The module shall also include a reversing contactor, local control switches, a graphical LCD, and LED indicators. All internal wiring shall be flame-resistant, rated 105 degrees C, and UL/CSA listed. Voltage shall be selectable via a jumper included on the power board.

3.4.3 Motor starter shall be in accordance with Appendix A – Valve Data Sheet and as follows:

A. Integral motor starter shall be provided in an NEMA 4 enclosure suitable for outdoor use sized to accommodate the starter and the components listed below.

B. Motor starter shall be 480VAC 60HZ 3 phase. Power source will be provided by the Government.

C. The starter shall be furnished with all components listed below, and all components shall be wired to a terminal strip mounted inside the starter enclosure and shall accommodate the interface wiring between the starter and the actuator:

1. Momentary type Open and Close pushbuttons with legend plates.

2. Position lights for Open, Intermediate and Closed. Lights shall be push-to-test type, 120 VAC LED lamps with legend plates.

3. Local/Off/Remote selector switch with legend plate.

4. Reversing Starter, with 120 VAC coils, sized to power and provide overload protection for the actuator motor.

IRA-3919 Page-10

5. 120 VAC, 1 Phase space heater with thermostat.

6. Control power transformer, 1 Phase, 480 VAC to 120 VAC.

Transformer shall be primary and secondary fused and sized to accommodate the components mounted inside the starter and the actuator.

IRA-3919 Page-10

3.5. Submittal Summary Table - The Contractor shall submit the following:

No. Section

Reference Submittal Description Due

1 3.3.16 Actuator and motor data sheets Within 2 weeks of notice of award

2 4.1 Valve Data Sheet including Cv, overall assembly dimensions, and overall assembly weight

Within 2 weeks of notice of award

3 4.1 Actuator Sizing Analysis Within 2 weeks of notice of award

4 4.1 Assembly Drawing with Maintenance Manual Prior to fabrication

5 4.2.1 Operational Test Prior to shipment 6 4.2.2 Hydrostatic Test Prior to shipment 7 4.2.3 Seat Leakage Test Prior to shipment 8 4.2.5 Test Reports Prior to fabrication

9 4.4 Factory Testing Prior to shipment

4. VERIFICATION

4.1 Engineering Analysis and Documentation: Contractor shall perform an engineering analysis to show valve and related components meet the requirements of this specification. Include a valve data sheet with Cv, assembly drawing, maintenance manual, and actuator sizing.

4.2 Testing: All testing shall be performed at the Contractor’s facility. The Government reserves the right to witness all tests. Provide Government 2 week notice.

4.2.1 Non Destructive Examination and Testing: Due to the severe operating service, extensive examination is required of the valve pressure boundary prior to manufacture/assembly. In addition to Vendor’s standard quality control procedures, the following testing shall be performed as a minimum. Test method and acceptance criteria shall be per ASME B16.34 unless more stringent criterion for rejection is specified below.

A. Castings shall be given an initial visual examination in accordance with MSS SP-55 with acceptance criteria as specified therein.

B. Valve body, bonnet, and cover shall undergo 100% volumetric examination of accessible areas in accordance with ASME B16.34.

1. Cast valve body/bonnet shall undergo radiographic examination.

2. Forged valve body/bonnet shall undergo radiographic or ultrasonic examination.

IRA-3919 Page-11

C. Valve surfaces shall undergo liquid penetrant examination of accessible areas as specified below:

1. 100% examination of hard facing on seat and disc shall be performed. Any cracks or linear indications shall be cause for rejection. More than a single hole greater than 1/32-in diameter per square inch shall be cause for rejection.

2. For castings, 100% of exterior and all accessible interior surfaces of the body, bonnet and cover shall be tested in accordance with B16.34.

3. For forgings, 100% of exterior and accessible interior surfaces of the body, bonnet, and cover shall be tested in accordance with B16.34. For forged carbon steel materials, 100% magnetic particle testing in accordance with B16.34 may be substituted for liquid penetrant testing.

4.2.2 Pressure Testing:

A. Valve shall be given a hydrostatic pressure test in accordance with ASME B16.34.

B. In general, valves with bypass shall be tested with bypass in place.

However, if the hydrostatic test of the main valve exceeds the test pressure of the bypass piping or the bypass valve, the test may be made without the bypass in place.

4.2.3 Operability Testing: After successfully completing the pressure test, the valve shall undergo 100 operating cycles from full open to full close. Valve shall operate smoothly with no indications of binding, sticking or indications of distortion during the pressure test.

4.2.4 Seat Leakage Testing: Contractor shall perform a valve seat leakage test to demonstrate the valve meets the requirements of Appendix A at the design pressure. Closure testing for all isolation valves shall meet the following:

A. Closure testing shall be performed in accordance with ASME B16.34 with acceptance criteria per MSS SP-61.

B. Closure testing shall be performed after hydrostatic pressure testing and operability testing.

C. The alternate low pressure gas seat closure test is not acceptable.

4.2.5 Test Documentation:

A. Certified material test report (CMTR) of actual chemical and physical tests, results of all supplementary testing required by the ASME or ASTM standards shall be submitted for review.

IRA-3919 Page-12

B. Certified and signed Nondestructive Examination Test Reports shall be submitted for each of the test specified herein. Reports shall include photographs or films of finding before and after any repairs

4.3 Cleaning and Drying: Valve shall be completely cleaned and dried after testing.

The valve shall be inspected to ensure all cavities have been drained of water.

4.4 Factory testing: Every actuator shall be factory tested to verify: rated output torque, output speed, hand-wheel operation, local control, control power supply, valve jammed function, all customer inputs and outputs, motor current, motor thermistor, LCD and LED operation, direction of rotation, microprocessor checks, and position-sensor checks. A report confirming successful completion of testing shall be included with the actuator.

4.5 Acceptance:

4.2.2 Government inspection: Upon receipt at AEDC the Government will inspect the valves and all related components for any visible damage, general cleanliness, craftsmanship, and adherence to final drawings.

4.2.3 Acceptance: The Government will accept the valve and all related components upon satisfactory operation at Arnold AFB, TN or 60 days after receipt at AEDC, whichever comes first.

5. PACKAGING

5.1 Preparation for Delivery: The valve and actuator shall be factory assembled and all preservation, packaging, and packing shall be provided to ensure safe delivery of the valve and related components to AEDC.

5.2 Post-Delivery Storage: All preservation, packaging and packing shall be such that the valve and related components can be stored on a pallet outdoors and sustain no damage from rain, sleet, snow, and hail.

6. NOTES - Not applicable.

IRA-3919 Appendix A-1

APPENDIX A

VALVE DATA SHEET

SERVICE

MEDIA Air Design Pressure 0 to 1230 PSIG Design Temperature -50°F to +1250°F

VALVE OPERATION Shut-Off ENVIRONMENTAL CONDITIONS Outside Installation/Un-Sheltered Temperature -10°F to +110°F Relative Humidity 20 to 100 % Barometric Pressure 13.7 to 14.5 PSIA

VALVE REQUIREMENTS

VALVE SIZE 8-Inch NPS TYPE / STYLE Gate / Parallel Slide VALVE DESIGN RATING Class 2500# END CONNECTIONS Butt Weld

VALVE LENGTH End-to-End – 30.00 inches per ASME B16.10

VALVE BODY MATERIAL

ASTM A182 F316H, ASTM A182 F347H,

or Approved Equal that meets required conditions and ASME B16.34 Cv Full bore

SEAT LEAKAGE MSS-SP-61

VALVE TORQUE to open and close To be determined by valve manufacturer

ACTUATOR REQUIREMENTS

ACTUATOR TYPE Electric Motor, with manual override

VALVE/ACTUATOR STROKE TIME

Open/Close and Close/ Open in 60 seconds maximum under full differential pressure @ maximum and minimum temperature

ACTUATOR TORQUE MARGIN 125% of Maximum Calculated Torque POWER SUPPLY (Government furnished) 480 VAC 60 Hz 3 phase

CONTROL POWER (from transformer) 120 VAC 60 Hz 1 Phase STARTER Integral

ENCLOSURE NEMA 4

VALVE ORIENTATION

AT INSTALLATION Valve shaft Vertical

END OF SPECIFICATION