11307-11-014_V232_Spec.pdf

11307-11-014

21 September 2017

ITEM SPECIFICATION FOR

HYDRAULICALLY ACTUATED 84-INCH

NPS 150 POUND CLASS HIGH PERFORMANCE BUTTERFLY VALVE ASSEMBLY

TO REPLACE VALVE VP-V232

ARNOLD ENGINEERING DEVELOPMENT CENTER

ARNOLD AIR FORCE BASE, TN 37389-9998

NOT SENSITIVE

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. Actuator Requirements

3.4. Controls and Instrumentation Requirements

4. VERIFICATION

4.1. Engineering Analysis

4.2. Test and Demonstration

4.3. Inspection

5. PACKAGING

5.1. Preparation for Delivery

5.2. Post-Delivery Storage

6. NOTES

Attachment A – Valve Data Sheet Attachment B – Installed Configuration (for reference only) Attachment C - Feedback Mounting

Table of Contents - 1

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1. SCOPE

1.1. This specification establishes the performance, design, manufacture, and verification requirements for a 84-inch NPS 150 pound class carbon steel butterfly control valve assembly with FCI 70-2 Class IV seat leakage rate. Valve assembly shall include hydraulic actuator, internal feedback transducer, limit switches, mating raised face weld neck flanges, and related mounting hardware.

2. APPLICABLE DOCUMENTS

2.1. Government Documents: None

2.2. Non-Government Documents: The following documents form a part of the specification to the extent specified herein.

2.2.2. American Society of Mechanical Engineers:

A. ASME B16.34-09 Valves-Flanged, Threaded, and Welding

End.

B. ASME/BPVC SEC VIII-1-11 Division 1 Rules for Construction of Pressure Vessels.

2.2.3 ASTM International:

A. ASTM A216-08 Specification for Steel Castings, Carbon, Suitable for Fusion Welding, for High- Temperature Service.

B. ASTM A516-10 Specification for Pressure Vessel Plates, Carbon Steel, for Moderate- and Lower- Temperature Service.

2.2.4 Fluid Controls Institute, Inc.:

C. FCI 70-2-06 Control Valve Seat Leakage.

3. REQUIREMENTS

3.1. General: Valve assembly, comprised of valve, actuator and related components, shall be designed, fabricated, assembled, tested and supplied in accordance with Section 2. Documents, Attachment A – Valve Data Sheet and as follows:

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3.1.1. Service: Valve, hydraulic actuator and related components shall be used to flow conditioned air in a piping system in accordance with Attachment A – Valve Data Sheet.

3.1.2. Corrosion Protection:

A. All stainless steel surfaces shall be free of iron contamination. If stainless steel castings are utilized, the manufacturer shall ensure that the sand used in the casting process is of high purity and free of iron or other impurities that could deposit onto the surfaces of the casting.

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

3.1.3. 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.

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, hydrocarbons, free iron, and other foreign matter and harmful contaminants.

3.1.5. Reliability:

A. Duty Cycle: The duty cycle for the valve/actuator assembly shall be 5000 cycles/year. A full cycle is defined as Closed-Open-Closed. The valve shall have an overshoot of less than 0.1 percent from the given command and a hysteresis/dead-band of less than 0.1 percent. The valve shall operate in this condition for 1000 hours per year.

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B. Design for a 25-year life and with a mean time between failures (MTBF) of not less than 2500 operating hours.

C. Valve shall maintain the FCI 70-2 class IV leak rate after 1000 cycles.

3.1.6. Maintainability: Design for a mean time to repair (MTTR) not greater than 16 hours for the valve and related components.

3.1.7. Transportability:

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

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

3.1.8. Nameplates & 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. Flow direction marking shall be prominently and permanently displayed on the valve indication flow direction.

3.2. Valve Requirements: Valve shall be in accordance with Attachment A Valve

Data Sheet and as follows:

3.2.1. Valve Body:

A. Integral cast body/flange or weld neck flanges welded to valve body is acceptable. Material: ASTM A216 GRWCB, ASTM A516 GR70, or Government approved equal.

B. Composite (i.e. built-up flange stiffeners) or slip-on flange construction is not acceptable.

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

3.2.2. Valve Disc/Plug:

A. Valve disc shall be of a double or triple offset design.

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B. Valve disc shall be capable of sealing in each direction.

C. Material: Material: ASTM A216 GRWCB, ASTM A516 GR70, or Government approved equal.

D. Disc to shaft connection shall form a rigid, vibration-free assembly suitable for meeting the pressure differential, aerodynamic torque and operator torques.

E. Attach disc to shaft by means of pins or keys. All pins, keys, and other materials used to secure disc to shaft shall be mechanically secured to prevent entry into the flow stream.

F. Roll pin connections are not acceptable.

3.2.3. Valve Seat/Seal:

A. Seat/seal material(s) shall be PTFE or Government approved equal and replaceable. Inflatable seals are not allowed.

B. Seat/seal shall be located on the upstream side of the shaft.

C. All pins, keys or other materials used to secure valve seat to valve body and the valve seal to the valve disc shall be mechanically secured to prevent entry into the flow stream.

D. Roll pin connections are not acceptable.

3.2.4. Valve Shaft/Stem:

A. Valve shall have a solid, one-piece shaft attached to the valve disc.

B. Material: 17-4 or Government approved equal.

C. Valve shaft shall have a 1/2-13 drilled and tapped hole located in the center of the shaft on each side. There shall be four drilled and tapped holes in the valve body to accept a rotary feedback. See Attachment C.

D. Valve shaft shall have a mechanical lockout/tagout (LOTO) for safe maintenance. The LOTO mechanism shall be capable of withstanding full system hydraulic pressure on the actuator in either commanded direction and not allow the valve shaft to rotate.

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E. Valve shall include provisions to accept a mechanical Kirk key to prevent disc movement during LOTO.

3.2.5. Valve Bearings:

A. Thrust bearings on both sides of the valve disc shall absorb thrust in both directions and maintain disc in its proper position.

B. Plated bearing surfaces are not allowed.

C. If applicable, valve bearing shall be located with the valve body. Outboard bearings are not acceptable.

3.2.6. Valve Packing and Glands:

A. Provide non-asbestos packing with a thermal rating as required in

Attachment A – Valve Data Sheet.

B. Provide adjustable glands on all shafts extending through the valve body that cannot be sealed with pressure tight caps.

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

D. Packing shall be included to prevent process air from entering the bushing/bearing area.

3.2.7. Lubrication: Design valve bushings and bearings to prevent the lubricant from entering or coming in contact with the flowing medium.

3.3. Actuator Requirements: Hydraulic actuator shall be in accordance with

Attachment A Valve Data Sheet and as follows:

3.3.1 Hydraulic actuator shall be rated to 3000 PSIG maximum working pressure.

3.3.2 Actuator shall be directly mountable to the valve operator arm to directly couple to the valve shaft. Supply all required mating hardware.

3.3.3 Valve actuator design shall not be of the scotch yoke type.

3.3.4 Design actuator such that the valve shaft, or a directly coupled extension of the valve shaft, is accessible on the outside face of the actuator.

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3.3.5 Design shall have no external moving parts for personal safety.

3.3.6 Design key/pin connection at the operator as the point of shear, or failure, to protect all internal components of the valve.

3.3.7 Provide 5 percent adjustable cylinder cushioning at both ends of cylinder travel.

3.3.8 Provide an internal position feedback transducer in accordance with Controls and Instrumentation Requirements.

3.3.9 Valve shall maintain a failsafe position of ± 5 percent of its current location when an electrical and/or hydraulic failure occurs.

3.3.10 Actuator shall have a visual percentage open/closed indication.

3.4. Controls and Instrumentation Requirements: Controls & Instrumentation shall be in accordance with Attachment A Valve Data Sheet and as follows:

3.4.1 Internal Position Feedback Transducer: Provide a linear variable differential transformer (LVDT).

A. Feedback transducer input voltage: +24 VDC nominal (± 3.5 VDC minimum range).

B. Feedback transducer analog current output: 4 to 20 mA into a minimum load of 600 ohms.

C. Feedback transducer shall provide the capability to perform user calibration (zero/span) of the 4 to 20 mA output.

3.4.2 Limit Switches: Provide limit switches and related mounting hardware to indicate valve full open and full close positions.

A. Limit switches shall be double pole double throw (DPDT) snap action, double break contacts shall be used.

B. Contacts shall be rated for 3.0 amps minimum at 24VDC.

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

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3.4.3 All other controls and instrumentation will be furnished by the Government. The following is provided for reference only:

A. The control system that is used to position the valve and its components requires the valve to move at a control frequency of 0.314 radians/second in small 5 percent increments with no greater than a 45 degree phase shift between the command and the feedback signals and requires the valve to make up to 80 percent (from 10 percent open to 90 percent open) large step changes in less than 2 seconds.

B. The control system sends a command signal to a pilot servo or proportional valve assembly located near the valve actuator system which is used to position the valve to its commanded position by porting hydraulic fluid to either the open or close side of the cylinder. See Attachment B – Typical Valve System Diagram as an example of the control system.

3.4.4 Mounting hardware requirements for government furnished controls and instrumentation (as applicable)

4. VERIFICATION

4.1 Engineering Analysis: Perform an engineering analysis to show valve and related components meet the requirements of this specification.

4.2 Pre-Shipment Test(s) and Demonstration(s):

A. Operational Test: Perform a valve assembly operational test verifying valve actuation of at least 10 cycles, stroke times, and cylinder cushioning, and demonstrating proper cylinder feedback transducer and limit switch operation.

B. Seat Leakage Test: Perform a valve seat leakage test to demonstrate that the valve meets the requirements of Attachment A at the design pressure.

The valve shall be opened and closed six times prior to performing seat leakage test. The seat shall be tested dry (as installed condition) with no lubricant to aid sealing. The test shall be performed in each direction in accordance with FCI 70-2.

C. Hydrostatic Pressure Test: Perform a hydrostatic test of the valve body in accordance with ASME B16.34.

4.3 Pre-Shipment Inspection(s): Contractor shall perform weld inspection in accordance with ASME B16.34.

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5. PACKAGING

5.1. Preparation for Delivery: Provide all preservation, packaging, and packing to ensure safe delivery of the valve and related components to AEDC.

5.2. Post-Delivery Storage: All preservation, assembly, packaging, and packing shall be such that the valve and related components are protected from rain, sleet, snow, and hail while stored on a pallet outdoors.

6. NOTES: Not Applicable

Attachment A - Valve Data Sheet Attachment B – AEDC Typical Valve System Diagram Attachment C – Feedback Mounting

Appendix A-1

ATTACHMENT A

VALVE DATA SHEET

SERVICE

MEDIA Air Operational Flow Conditions 3 to 87 PSIA Max Operational Differential Pressure 87 PSID Min Required Sealing Pressure 213 PSID Design Temperature -10°F to +300°F Design Flow Rate 1012 lbm/s at atmospheric conditions

VALVE OPERATION Open or Closed ENVIRONMENTAL CONDITIONS Inside Installation/Sheltered Temperature -10°F to +110°F Relative Humidity 20 to 100 % Barometric Pressure 13.7 to 14.5 PSIA

VALVE REQUIREMENTS

VALVE SIZE 84-inch NPS TYPE High Performance Butterfly VALVE DESIGN RATING ASME B16.34 Class 150#

END CONNECTIONS

Double Flanged ASME BPVC SEC VIII-1, Appendix II

Raised Face Flange VALVE LENGTH (Face to Face) 36.00 inch VALVE BODY MATERIAL Carbon Steel Cv 405,000-415,000

PRESSURE DROP ACROSS VALVE DISC < .15 PSI

SEAT LEAKAGE Class IV (each direction) FCI 70-2 DUCT SYSTEM I.D. 84.00 inch DUCT SYSTEM O.D. 84.75 inch

Appendix A-2

ACTUATOR REQUIREMENTS

ACTUATOR TYPE Hydraulic Cylinder(s)

VALVE/ACTUATOR STROKE TIME

• Open/Close and Close/ Open in

3.0 seconds maximum under full differential pressure @ maximum temperature.

• 3.0 second stroke time includes cylinder cushion.

HYDRAULIC SUPPLY

(Government furnished)

• Supply pressure @ servo valve:

1200 psig max.

• Vickers direction valve @ 1000 psid: 45 gpm.

• Hydraulic Oil: Mobil DTE 24 CYLINDER PORTS SAE O-Ring Type

VALVE/ACTUATOR REQUIREMENTS

VALVE/ACTUATOR ORIENTATION

@ INSTALLATION

Valve Shaft Horizontal Actuator on Right looking Inlet to Outlet

Appendix B-1

ATTACHMENT B

TYPICAL VALVE SYSTEM DIAGRAM (FOR REFERENCE ONLY)

VALVE BODY

EXISTING

DUCTING

EXISTING

DUCTING

DIGITAL SERVO VALVE

CONTROLLER (PLC)

CONTROL SYSTEM (PLC)

CYLINDER

KEY

Government Furnished (Existing) Equipment

Contractor Supplied Objects

MATING

FLANGE CYLINDER

FEEDBACK

MATING

FLANGE

DIRECTIONAL VALVE

ASSEMBLY

COMMAND

SIGNAL

4 – 20mA

LIMIT SWITCH FEEDBACK

Appendix C-1

ATTACHMENT C

FEEDBACK MOUNTING

END OF SPECIFICATION