11307-17-003_VKF_Valve_314_Spec.pdf

11307-17-003 NOT SENSITIVE

SPEC NO. 11307-15-003

16 January 2017

Valve No. 314

ITEM SPECIFICATION FOR

HYDRAULICALLY ACTUATED 30-INCH NPS CLASS 150 HIGH

PERFORMANCE BUTTERFLY VALVE ASSEMBLY

SUPPLIED WITH MATING FLANGES

ARNOLD ENGINEERING DEVELOPMENT COMPLEX

ARNOLD AIR FORCE BASE, TN 37389-9998

NOT SENSITIVE

IRA-1693

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. Hydraulic Actuator Requirements

3.4. Controls and Instrumentation Requirements

3.5. Additional Hardware to be Supplied by Contractor

4. VERIFICATION

4.1. Verification of Structural Adequacy

4.2. Welding Inspection

4.3. Additional Special NDE

4.4. Hydrostatic Pressure Test

4.5. Valve Closure / Seat Leakage Test

4.6. Operational Test

5. PACKAGING

5.1. Preparation for Delivery

5.2. Post-Delivery Storage

6. NOTES - Not applicable

Appendix A – Valve Data Sheet

Appendix B - Views of the Existing Valve/Actuator Assembly

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1. SCOPE

1.1. This specification establishes the performance, design, manufacture, and verification requirements for a complete assembly consisting of a 30-inch NPS ASME class 150, carbon steel hydraulically-actuated butterfly valve (non-modulating) per ASME B16.34 with FCI 70-2 Class V bi-directional seat leakage equipped with open and closed limit switches. A manual operator is not required.

The complete assembly shall be delivered to Arnold AFB, TN as a unit.

2. APPLICABLE DOCUMENTS

2.1. Government Documents: None

2.2. Non-Government Documents:

2.2.1 American Society of Mechanical Engineers:

A. ASME B16.10-09 Face-to-Face and End-to-End Dimensions of Valves.

B. ASME B16.20-12 Metallic Gaskets for Pipe Flanges Ring-Joint, Spiral-Wound, and Jacketed.

C. ASME B16.34-13 Valves – Flanged, Threaded, and Welding End.

2.2.2 ASTM International:

A. ASTM A193-14 Specification for Alloy-Steel and Stainless Steel Bolting for High Temperature or High Pressure Service and Other Special Purpose Applications.

B. ASTM A194-14 Specification for Carbon and Alloy Steel Nuts for Bolts for High Pressure or High Temperature Service, or Both.

2.2.3 Fluid Controls Institute, Inc.:

A. FCI 70-2-13 Control Valve Seat Leakage.

2.2.4 Manufacturers Standardization Society of the Valve and Fittings Industry:

A. MSS SP-25-13 Standard Marking System for Valves, Fittings, Flanges, and Unions.

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3. REQUIREMENTS

3.1. General: The valve assembly shall be designed, fabricated, assembled, inspected, tested, supplied, and documented in accordance with this specification (including appendices) and Section 2 Applicable Documents.

3.1.1. Service: The valve assembly will be used to flow conditioned air in a piping system in accordance with Appendix A – Valve Data Sheet. The valve assembly with fast-acting actuator will replace an existing 60 year old valve (see Appendix B) and will function as a process air configuration valve (fully open or fully closed).

3.1.2. Geometry: This specification does not attempt to strictly define the available envelope into which the extents of the valve assembly shall fit. The area around the valve is reasonably open and there is flexibility with installation options. The Contractor shall design the valve such that the main shaft is oriented horizontal to the ground. The best likely orientation of the actuator is with its long axis perpendicular to flow with the long end toward the ground. However, upon request, the Contractor shall re-orient the actuator by clocking it 90, 180, or 270 degrees about the main shaft during the design phase at no additional cost the Government. (Once the preliminary drawings are approved, the orientation of the actuator vs. the valve shall be considered “set.”)

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

3.1.4. 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 valves in service.

C. A valve disc position (0-90 degrees) indicator shall be provided external to the valve for visual determination of disc position. The indicator shall have 10 degree (or less) scale divisions.

3.1.5. Workmanship: All equipment shall be constructed and finished in such a manner that no sharp edges, burrs, or physical defects are present. Materials shall be new and unused.

3.1.6. Reliability:

A. The valve assembly shall be designed for a 25 year life (minimum).

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B. The valve assembly shall have a minimum life of 100,000 cycles. A full cycle is defined as Closed-Open-Closed.

3.1.7. Maintainability: Provide manufacturer’s information showing a mean time to repair (MTTR) not greater than 40 hours for the valve, actuator, and related components using the valve industry standard definition of MTTR based on valve installations similar to that of this valve.

3.1.8. Nameplates:

A. The valve body shall have a corrosion-resistant nameplate affixed meeting the requirements of MSS SP-25 with the following (minimum) information:

Manufacturer’s name, address, type or style, model number, serial number, standards, manufacture date, size, ASME Class, Cv, maximum allowable pressure at 300 degrees F, maximum allowable shut-off pressure, body material, trim materials. In addition, the nameplate shall indicate per ASME B16.34 that the NDE required of special class valves was performed.

B. The actuator shall have a corrosion-resistant nameplate affixed with all pertinent industry-standard information including the following information (minimum): Manufacturer’s name, address, type or style, model number, serial number, ANSI/NFPA standards, manufacture date, bore, stroke, rod diameter, pressure rating, seal material, fluid type (Mobil DTE 24).

C. Other major components such as limit switches and transducers shall have pertinent product information affixed as per standard industry practice.

3.1.9. Markings: Markings shall be prominently and permanently displayed on the valve.

All body markings required by ASME B16.34 shall be included. ASME B16.34 paragraph 4.2.6 “Omission of Markings” shall not apply.

3.1.10. Transportability: Permanent lug(s) shall be provided for lifting the valve assembly (with actuator installed) located with respect to its center of gravity (cg) in its installation orientation by crane.

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

3.2.1. Locking: Provide a mechanical locking feature to secure valve/actuator assembly in fully closed and in fully open positions for lockout-tagout purposes. The locking assembly shall be structurally adequate, meeting applicable industry standard code safety factors, to resist the maximum force that can be generated by the hydraulic actuator. It shall accept a removable key lock (lock provided by the Government) to prevent tampering.

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3.2.2. Valve Body and Flanges:

A. The body shall be of the ASME B16.34 butterfly type using plate, cast, or forged carbon steel.

B. Flanges shall conform to the requirements of ASME 16.47 for 30-inch Class

150. Valve body flanges, (either cast or forged carbon steel) shall be integral to the body or of the weld neck type full penetration butt-welded to the body.

C. Lug or wafer valve body design is not acceptable.

3.2.3. Trim:

A. The trim shall be of triple-offset design and rated for the full class 150 pressure rating.

B. The trim shall seal bi-directionally with seat leakage rate per FCI 70-2 Class V.

C. Appendix B shows photographs of the existing valves that will be replaced.

The direction of flow through the valve is also shown.

D. Failure mode: The failure mode is not applicable to this specification though the plan is to install the valve in an orientation such that the normal flow stream would tend to close the valve. Failure modes which do not include the loss of hydraulic pressure will be controlled by the Government supplied hydraulic control cabinet which will cause the valve to open if a health signal is lost.

E. Valve Disc:

1. The material of construction shall be carbon steel (excluding seal).

2. The disc-to-shaft connection shall form a rigid joint suitable for meeting the pressure differential, aerodynamic torque, and operator torque by means of keys, pins, or spline. All materials used to secure disc to shaft shall be mechanically secured to prevent entry into the flow stream. Roll pin connections are not acceptable. Differential thermal expansion shall be considered in the connection design.

F. Valve Seat and Seal:

1. The valve seat and seal material(s) shall be non-corrosive metal, unpainted/non-coated, and rated for the valve design temperature range.

2. The seal rings shall be removable. Pins, keys or other materials used to secure the valve seat to the valve body and the valve seal to the valve disc shall be mechanically secured to prevent entry into the flow stream. Roll pin connections are not acceptable.

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G. Valve Shaft: The valve shaft shall be made of a heat treatable stainless steel such as 17-4 PH. Special attention shall be given to the material selection of the shaft and bearings to prevent galling of the shaft. The shaft shall be designed so as NOT to be a wear component.

H. The fastening design used in the valve interior shall not allow any valve components including fasteners to loosen and enter the flow stream. The use of safety wire is not allowed.

3.2.4. Bearings and Bearing Holders:

A. The shaft housings shall be integral to the valve housing. Pillow block type bearings are not allowable.

B. A thrust bearing (or bearings) shall absorb thrust in both directions and maintain the disc in its proper position. Special attention shall be given to the design to minimize wear and prevent galling of the sliding surfaces providing for a long life of the components involved.

C. Plated or coated bearing surfaces are not acceptable.

3.2.5. Valve Packing and Packing Gland:

A. Non-asbestos packing with a thermal rating as required in Appendix A – Valve Data Sheet shall be provided.

B. The packing gland shall be adjustable and capable of being repacked externally without disassembly of any part of the valve other than the gland itself.

C. There shall be no visible water leakage through the packing at the valve’s 70 degrees F class 150 pressure rating during factory acceptance testing.

D. The packing shall be of a material commercially available and sufficiently described in the drawings such that it can be purchased directly from a distributor.

3.2.6. Lubrication: Valve bushings and bearings shall prevent the lubricant from entering or coming in contact with the flowing medium.

3.3. Hydraulic Actuator Requirements: Hydraulic actuator shall be in accordance with Appendix A – Valve Data Sheet and as follows:

3.3.1. The actuator shall be rated for 3000 psig MAWP (maximum allowable working pressure).

3.3.2. The design basis shall assume a 1200 psig supply of hydraulic fluid.

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3.3.3. The actuator and its structural supports shall be mounted to the valve body. To rotate the valve shaft/disc, the actuator shall use one double acting hydraulic cylinder with rod attached either to a 1) pin-connected moment arm link connected to the valve shaft or 2) rack and pinion mechanism. Supply all required mating hardware.

3.3.4. The actuator mechanism shall be sufficiently pinned to prevent racking when quickly switching directions of disc movement.

3.3.5. A spring return device shall not be used in the actuator design.

3.3.6. The Contractor shall provide a cylinder with adjustable cylinder cushioning at both ends of the cylinder stroke. The cushioning shall not adversely affect the travel time over the non-cushioned range of motion.

3.3.7. At maximum conditions of process air pressure differential and temperature and hydraulic fluid anywhere in the range of +20 to 120 degrees F, the valves/actuators shall travel from 10% open to 90% open in 3.0 seconds or less, from 90% open to 10% open in 3.0 seconds or less, and 0.5 second or less in each of the following ranges (which includes the cushions): 0% to 10%, 90%- 100%, 100%-90%, and 10%-0%. The Contractor may assume an adequate supply of hydraulic fluid is available at 1200 psig to meet this requirement. The Contractor shall verify by analysis the cylinder ports and Contractor supplied hydraulic hoses do not prevent operation at this speed. The nominal size of the ports and hydraulic supply hoses shall be 3/4 inch minimum.

3.3.8. The actuator shall be sized to provide a force that is at least 25% larger than the maximum anticipated loadings in each direction while maintaining appropriate safety factors on material strength.

3.3.9. To enhance maintainability of the actuator, the hydraulic cylinder shall meet all applicable National Fluid Power Association (NFPA) standards and be of a commonly-available NFPA-style design including port sizes and locations, mounting style and dimensions, bore and rod diameter combination, and piston seal type.

3.3.10. The cylinder rod shall be polished stainless steel.

3.3.11. Ensure all parts of the cylinder including the seals are compatible with the hydraulic fluid, MOBIL DTE 24. The seals shall be leak-free at 3000 psi and suitable for dynamic sealing in addition to static sealing.

3.3.12. Ensure the cylinder is properly aligned in the actuator assembly to minimize the chance of potential damage to piston rod, rod bearings and seals.

3.3.13. The actuator shall be removable from the valve while the valve is installed in the duct.

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3.3.14. The stroke length of the actuator shall enable the full 90 degree rotation of the valve to be realized (i.e. the valve shall fully open/fully close; “short-stroking” is not allowable).

3.3.15. The hydraulic tie in points to the Government supplied hydraulic system shall be FNPT fittings rated for 3000 psi minimum. The tie in point shall be anchored at a static location on the actuator mechanism or valve body. The Contractor shall supply flexible hose as required to accommodate cylinder movement. The hose diameter shall be rated for 3000 psi, if hose is required. Care shall be taken for routing hoses such that the manufacturers minimum bend radius is not violated over the entire travel of the cylinder.

3.4. Controls and Instrumentation Requirements: The valve will be positioned using a control system that will be largely provided by the Government but with some components of the control system provided by the Contractor.

3.4.1 Limit Switches: Provide two limit switches mounted externally to the actuator assembly actuated directly by the valve shaft, factory adjusted to indicate valve full open and full closed positions, and proper operation verified at factory.

A. For proper functionality and compatibility with existing AEDC spare parts inventory, limit switches shall be as specified below having the following characteristics: side rotary momentary action, double pole double throw (DPDT), 15 degrees max pretravel, 60 degrees minimum over travel, 7 degrees maximum differential travel, 4 inch-pound maximum operating torque, 4 inch-pound maximum full travel torque, fluorosilicone seals, NEMA 4 rated, plug-in base receptacle, 3/4-inch conduit connection w/fitting, 6 feet long cable, lever to have 3/4-inch diameter by 1/4-inch wide steel roller and 1.5-3.5 inch adjustment range; contacts rated for 3.0 amps minimum at 24VDC. Specifically, the following parts or Government approved equal are required:

1. Switch: the switch portion of Honeywell/MicroSwitch P/N LSYAB2B switch/base receptacle assembly (base receptacle to be removed and not used).

2. Base receptacle: Honeywell/MicroSwitch P/N LSZ4002M plug-in base receptacle which includes 6 feet long cable. (This base receptacle shall replace the base receptacle of the LSYAB2B.)

3. Lever: Honeywell/Micro Switch P/N LSZ52D.

B. Limit switch attachment shall allow the automatic reset of the switch if the valve over-travels.

3.4.2 For information only: A single Government/Contractor interface point, such as with wiring terminated in a junction box, is not required. Existing conduit will be rerouted as required by the Government.

3.4.3 All other controls and instrumentation will be furnished by the Government.

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3.5. Additional Hardware to be Supplied by Contractor:

3.5.1 A pair of mating weld neck duct flanges per ASME 16.47 of the same 150# class with 37.5 degree weld-prep bevel for a 30” Inside Diameter, 0.375 inch thick duct.

Flanges shall be fabricated from ASTM A106 carbon steel. NOTE: This is not a standard size of pipe.

3.5.2 Duct flange gaskets.

3.5.3 Duct flange fasteners.

3.5.4 A Certified Mill Test Report per the applicable ASTM standard shall be supplied for each type of item supplied.

4. VERIFICATION

4.1 Verification of Structural Adequacy: Provide analysis showing:

4.1.1 The disc and shaft connection is structurally adequate, meeting applicable industry standard code allowable stresses, for the pressure differential and actuator loadings.

4.1.2 The valve body and flanges meet the ASME B16.34 class 150 pressure rating.

4.1.3 The structural adequacy of the disc, shaft, shaft housings, and bearings for the situation where the disc is nearly closed (but not seated) and subjected to the full class 150 rating pressure differential.

4.1.4 The structural adequacy of the actuator assembly including supports for the maximum loadings.

4.1.5 The adequacy of the thrust bearing design to minimize wear and galling.

4.1.6 Actuator sizing calculations as follows:

A. The Contractor shall demonstrate the NFPA cylinder he selects is designed per the requirements for the actuator listed herein. The supply pressure shall be assumed to be 1200 psi. The return line backpressure downstream of the hydraulic manifold to the sump will be limited to 50 psig maximum. If the Contractor determines through calculations and analysis that the maximum fluid displacement allowed in the cylinder by the specification is too small, then he shall notify the Contracting Officer. He shall include his calculations and recommended cylinder.

B. Calculation showing (while the hydraulic flow circuit is in the position control mode) the actuator can maintain the valve disc in the closed position with flow media (air) differential pressure of 220 psid across the disc with the larger air pressure on the side of the disc acting to try to open the valve.

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C. Calculation showing (while the hydraulic flow circuit is in the position control mode) the actuator can open the valve disc initially in the closed position with flow media (air) differential pressure of 220 psid across the disc with the larger pressure on the side of the disc acting to try to keep the valve closed.

D. The lock shall be shown by analysis to be strong enough to take the full force of the hydraulic cylinder at 1200 psig.

4.2. Welding Inspection: Inspection of all welds shall be performed in accordance with

ASME B16.34:

4.3. Additional Special NDE: In addition to the ASME B16.34-required examination / inspection for “standard” valves, the Contractor shall perform NDE and remove any defects found per ASME B16.34 Section 8 “Requirements for Special Class Valves”.

4.4. Hydrostatic Pressure Test: A hydrostatic test of the valve body (with disc open or partially open) shall be performed in accordance with ASME B16.34. If leakage through the shaft seals/packing occurs, a subsequent test shall be performed to show that the shaft seals/packing do not leak (no visible water leakage) at the valve’s Class 150 pressure rating at 70 degrees F. The Contractor shall supply all equipment necessary to perform the test. The shell pressure test can be conducted using standard blind flanges bolted to the valve flanges. Note:

Clamping of the valve flanges between two plates is not permissible.

4.5. Valve Closure / Seat Leakage Test: The valve shall be opened and closed six times prior to performing this test. A valve seat leakage test shall be performed per FCI 70-2 in each direction using FCI 70-2 Class V leakage rate criteria.

Perform the test in both directions with the pressure at the maximum shut-off differential pressure listed in Appendix A. The disc/seat shall be tested dry (as installed condition) with no lubricant to aid sealing. The force developed by the device that keeps the valve closed during the test shall not be greater than the force that would be generated by the valve’s hydraulic actuator with 1200 psi supply. The Contractor shall supply all equipment necessary to perform the test.

Valve shall be completely cleaned and dried after testing. The valve shall be inspected to ensure all cavities are drained of water.

4.6. Operational Test: In addition to any standard operational tests the valve and actuator manufacturers typically perform on their products, a series of operational tests shall be performed to verify the valve/actuator assembly will perform acceptably in the actual installed piping system. The fluid used in the test shall be Mobil DTE 24. Ensure the fluid is not contaminated. The supply pressure shall be set at 1200 psig. The Contractor shall supply all equipment necessary to perform the tests. For all tests involving actuator movement, movement shall be smooth and no binding shall occur. Also, for tests involving actuator movement, provide graphical results showing the pertinent test

Page-10 parameters vs. time. Cylinder inlet and outlet pressures shall be included in the graphical results.

A. It shall be demonstrated that the limit switches are properly adjusted and operating correctly and that the valve is not “short-stroked”. (The hydraulic fluid temperature is not important for this test.)

B. In each direction, demonstrate that the cylinder seals are leak-free with 1200 psid across the piston.

C. For this test, the valves and actuators assembly shall be assembled and be tested as a unit. The valve shall be stroked from 0% to 100% open to 0% continuously for 30 cycles. Actuation times shall be measured and recorded. Travel times shall be less than or equal to 3.0 seconds in the non-cushioned range and approximately 0.5 second in each of the cushioned ends for a total allowable time of 4.0 seconds or less during the 0% to 100% open stroke. The same time requirements apply during the 100% open to 0% stroke.

5. PACKAGING

5.1 Preparation for Delivery: The valve assembly shall be delivered to AEDC as a complete unit. All preservation, packaging, and packing shall be provided to ensure safe delivery of the valve assembly and the 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, hail, small animals and insects.

6. NOTES: Not Applicable

Appendix A-1

APPENDIX A

VALVE DATA SHEET

SERVICE

Flow media Air Design pressure / Required Class 220 PSIA / Class 150 Design temperature -10°F to +300°F Max shut-off differential pressure each direction (See note 1)

220 PSID

Cv 30,000 min Design Flow case Mass flow rate of 300 lbm/sec with upstream conditions of 119 psia and 50°F with valve fully open; pressure loss across valve < 0.6 psi.

Valve operation Fully Open; fully Close (non-modulating) Environmental conditions Outside installation/unsheltered

Temperature -10°F to +110°F Relative humidity 20 to 100 % Barometric pressure 13.7 to 14.5 PSIA

VALVE REQUIREMENTS

Valve size 30-inch NPS Type High Performance Butterfly Valve design code ASME B16.34 Valve rating (including trim/internals) Class 150 End connections Not Specified. Contractor shall supply

150# mating weld-neck duct flanges per

ASME 16.47

Body material Carbon steel; See para 3.2.2 Trim Triple Offset Seat leakage (max) FCI 70-2 Class V.

Shaft/packing leakage (max) See Specification Mating pipe size & material (non-standard) 30 inch ID, 0.375” thick wall, CS

ACTUATOR REQUIREMENTS

Actuator type Hydraulic cylinder, double-acting (fluid pressure applied in both directions), attached to moment arm or rack & pinion. Manual operator not required.

Max differential pressure across disc for design of actuator

Must open/close against max shut-off differential pressures listed above.

Appendix A-2

Hydraulic operating pressure 1200 psi normal Oil Type Mobil DTE 24 Cylinder ports SAE O-ring type Contactor-supplied hydraulic piping connections interface

NPT pipe or pipe couplings (min.

acceptable size is 3/4-inch NPT)

Safety Actuator shall have a mechanical lock at the full open and full closed position for Lockout-Tagout purposes.

Notes

1. Although the valve design pressure and max shut-off pressure are less than the required class 150 rating, the entire valve including trim (but not including actuator) shall be designed for the full class 150 pressure rating.

2. The valve must be capable of satisfying the flow case shown above in addition to meeting the Cv requirements. There is no minimum defined controllable flow requirement.

Appendix B-1

APPENDIX B

VIEWS OF THE EXISTING VALVE/ACTUATOR ASSEMBLY

Valve 314: From each side of duct

END OF SPECIFICATION AND APPENDICES