ATTACH-1-_Item-Spec.pdf

13787-14-001 NOT SENSITIVE

SPEC NO. 13787-14-001

13 February 2014

ITEM SPECIFICATION FOR MOTORIZED

144-INCH DIAMETER

BUTTERFLY VALVE ASSEMBLY

ARNOLD ENGINEERING DEVELOPMENT COMPLEX

ARNOLD AIR FORCE BASE, TN 37389-9998

NOT SENSITIVE

IRA-1041

ATTACHMENT #1

ATTACHMENT #1

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. Construction

3.3. Valve Requirements

3.4. Electric Motor Actuator Requirements

3.5. Controls and Instrumentation Requirements

4. VERIFICATION

4.1. Engineering Analysis

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

4.3. Pre-Shipment Inspection(s)

5. PACKAGING

5.1. Preparation for Delivery

5.2. Post-Delivery Storage

6. NOTES

Appendix A – Valve Data (2 pages)

Appendix B - Figures

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1. SCOPE

1.1. This specification establishes the performance, design, manufacture, and verification requirements for a 144 inch diameter steel butterfly control valve assembly per AWWA C516. Valve assembly shall include electric motor and gearbox actuator assembly, internal position feedback transducer, and limit switches. The valve shall have welding ends.

2. APPLICABLE DOCUMENTS

2.1. Government Documents: None

2.2. Non-Government Documents:

2.2.2. American Society of Mechanical Engineers:

A. ASME BPVC SEC II-D-13 Properties (Customary) Materials.

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

C. ASME BPVC SEC VIII-1-13 Rules for Construction of Pressure Vessels.

2.2.3 American Water Works Association:

A. AWWA C516-10 Large-Diameter Rubber-Seated Butterfly Valves, Sizes 78 In. and Larger.

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 the requirements herein.

3.2. Construction: The valve shall be constructed in accordance with AWWA C516.

Cast iron body and disc materials shall not be permitted.

3.2.1. Service: Valve, electric actuator and related components shall be used to flow conditioned air bi-directionally in an outdoor duct system in accordance with Appendix A – Valve Data Sheet.

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3.2.2. Corrosion Protection:

A. All stainless steel surfaces shall be free of iron contamination. If stainless steel castings are utilized, the Contractor 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 in accordance with Section 4.5 of AWWA C516 to preclude rust and corrosion.

3.2.3. Human Factors Engineering:

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

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

3.2.4. 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.

3.2.5. All components and materials shall be new, unused, and meet the requirements of the applicable referenced standards.

3.2.6. The Contractor shall design the valve assembly such that the maximum flow condition stated in Appendix A will not excite any low frequency modes of vibration that could adversely affect the functionality and/or the life of the valve components

3.2.7. Reliability:

A. Duty Cycle: The duty cycle for the valve/actuator assembly shall be 250 cycles/year. A full cycle is defined as Closed-Open-Closed. Up to two cycles may be completed in a day.

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B. Design for a 25-year life with a mean time between failures (MTBF) of not less than 1250 cycles.

C. Valve seat shall maintain its integrity for 1250 cycles.

3.2.8. Maintainability: Design for a mean time to repair valve seal (MTTR) not greater than 24 hours.

3.2.9. Transportability:

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

B. Permanent lug(s) shall be provided for lifting valve assembly with a crane through the center of gravity in its installation orientation (shaft horizontal).

Provide markings to identify the lifting load.

3.2.10. Nameplates & Markings:

A. Valve actuator and valve body shall have the respective manufacturer’s name, address, type or style, weight, model number, serial number, and catalog number stamped or engraved on a corrosion-resistant nameplate permanently secured to the equipment. Include pressure rating and flow capacity (Cv) on the valve plate.

B. Flow direction marking shall be prominently and permanently displayed on the valve indicating preferred flow direction.

3.3. Valve Requirements: Valve shall be in accordance with Appendix A Valve Data

Sheet and as follows:

3.3.1. Valve Body:

A. The valve body components shall be fabricated per AWWA C516. The valve body components shall be made of SA-516 Gr 70 plate or cast from SA-216 Gr WCB in accordance with ASME SEC II-D.

B. The open ends of the valve body shall be prepared for welding to the mating duct described in Appendix A with a 37.5 degree bevel for external welding. If the valve body is thicker than the adjacent duct ends, the ends shall be beveled 1:4 to the thickness of the adjacent duct. (see Appendix B, Figure B-1).

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C. The valve assembly shall be designed to be supported completely by its welded connections to the adjacent ducting.

D. Principle design stresses shall not exceed one-fifth of the ultimate or one-third of the yield strength of the material used when valves are operating under the maximum conditions for temperature and pressure and under the maximum ducting forces defined in Appendix B, Figure B-2:

3.3.2. Valve Disc:

A. Valve disc shall be fully capable of sealing in each direction and shall provide adequate flow in each direction to meet the overall flow requirement of Appendix A.

B. Material: SA-216 GR WCB, SA-516 GR70 in accordance with ASME SEC II-D, or Government approved equal.

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

D. Disc shall be attached to the 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.

E. Roll pin connections are not acceptable.

3.3.3. Valve Seat/Seal:

A. The seal material shall be resilient style and replaceable such that replacement can be accomplished without having to remove the valve from the duct.

B. The valve shall have a stainless steel seal to seal against the resilient seal.

C. The resilient material may either be attached to the valve disc or to the valve body.

D. Seat/seal shall be located on the downstream side of the shaft with the actuator located on the left when looking inlet to outlet of primary flow direction.

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

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F. Roll pin connections are not acceptable.

3.3.4. Valve Shaft/Stem:

A. Material: SA-564 Type 630 in accordance with ASME SEC II-D or Government approved equal. The Contractor shall design the shaft with a hardness with respect to the bearing material to prevent galling.

B. Valve shaft shall have a mechanical lockout/tagout (LOTO) for safe maintenance. The LOTO mechanism shall be capable of withstanding full system torque on the actuator in either commanded direction and not allow the valve shaft to rotate. The LOTO mechanism shall be designed to lock the valve both fully opened and fully closed.

3.3.5. Valve Bearings:

A. Thrust bearings shall absorb thrust in both directions and maintain disc in its proper position.

B. Plated bearing surfaces are not allowed.

C. Bearings shall require no external heating or cooling equipment.

3.3.6. Valve Packing and Glands:

A. Provide non-asbestos packing with a temperature rating as required in Appendix A – Valve Data Sheet.

B. Provide adjustable glands on the shaft 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.

3.3.7. Bearing and Shaft Lubrication (if used): Design of the valve bushings and bearings shall prevent the lubricant from entering or coming in contact with the flowing medium. Any lubrication fittings shall be externally accessible for maintenance.

3.4. Electric Motor Actuator Requirements:

3.4.1 Electric motor actuator shall be Limitorque L120 series or approved equal in accordance with Attachment A – Valve Data Sheet and as follows:

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A. 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.

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

C. Electric motor actuator package shall be contained in a weatherproof enclosure (NEMA 4, NEMA 4X, and IP67) suitable for operation in an unsheltered outdoor environment.

D. Electric motor actuator shall be suitable for mounting in the horizontal position.

E. Electric motor shall be specifically designed for valve actuator service and shall be of high starting torque, totally enclosed, non-ventilated construction.

1. 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.

2. Motor shall be of sufficient size to open or 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 five complete cycles (open-close-open, or close-open-close) every 15 minutes without exceeding its temperature rating.

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

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

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

F. Actuator shall be a single or multiple reduction unit with power gearing consisting of spur, helical or bevel gears and/or worm gearing.

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

2. Nonmetallic, aluminum or cast gearing shall not be allowed.

3. All gears and shafting shall be supported on anti-friction tapered roller bearings.

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

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

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6. 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.

7. All lubricants shall be suitable for service conditions.

8. Actuator shall have a built-in device (independent of gear backlash), incorporated in the drive train, to permit load impact under dynamic efficiency conditions, with a hammer blow effect, to allow the motor to reach full speed before engaging the valve load.

9. 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.

10. 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, or 60 pounds for running load. Movement from motor operation to hand wheel operation shall be accomplished by a positive declutch lever which mechanically disengages the motor and related gearing.

Design such that simultaneous manual and motor operation cannot occur. Friction type declutch mechanism is not acceptable.

11. Provide torque switch that will interrupt the control circuit in both the opening and closing directions when valve torque overload occurs or when valves require torque seating in the closed or open position.

Contacts shall be wired to an internal terminal strip. Contacts shall be silver or silver-plated having a minimum rating of 10 amperes (break) inductive at 120VAC. Torque switch shall be independently adjustable for both open and close directions of travel, with a positive means to limit the adjustability so as not to exceed the actuator output torque capability. Torque switch design shall permit visible verification of switch position without disassembly.

12. Provide internally adjustable limit switches at open and closed positions. Position limit switches and the associated gearing shall be an integral part of the actuator and shall be fully enclosed. Limit switch gearing shall be driven directly from the actuator drive sleeve, remain synchronous with valve position and functional at all times, whether the unit is operated electrically or manually. Gearing shall be made of bronze or stainless steel, grease lubricated and totally enclosed to prevent dirt and foreign matter from entering the drive train. Switches shall be field adjustable, allowing for trip points from fully open to fully closed positions or any intermediate point of valve

Page-8 travel. Switches shall not be subject to breakage or slippage due to over-travel. Limit switch contacts shall be heavy-duty, silver or silver-plated having a minimum rating of 10 amperes (break) inductive at 120VAC, with wiping action. Contacts shall be wired to an internal terminal strip. Use of cams or setscrews in securing switches or the drive system is unacceptable. Limit switch design shall permit visual verification of switch position without disassembly. Limit switches shall have 2 percent maximum dead band.

13. Provide motor with thermal overload protection and an internal 1-phase, 60 hertz, 120 volt space heater with thermostat.

14. Provide electrical compartment with an internal 1-phase, 60 hertz, and 120 volt space heater with thermostat.

15. In the event of a loss of power to the actuator motor with the disc in an intermediate position between fully open and fully closed, the actuator shall prevent the disc shaft from opening or closing more than 5% of stroke in either direction. This requirement to maintain position shall assume pneumatic loads are being applied to the disc at the maximum flow and maximum differential pressure conditions as defined in Appendix A.

G. Primary power to the actuator shall be 480 VAC, 3-phase, 60 hertz.

Control power shall be 120 VAC, 1-phase, 60 hertz. Both of these power sources will be provided by the Government.

H. Reversing Combination Starter will be provided by Government and will include all necessary pilot lights, pushbuttons and selector switches to control the valve locally or remotely.

3.5. Controls and Instrumentation Requirements:

3.5.1 Contractor shall provide a R/I Converter to send remote valve position and indication via 4-20 mA signals. It shall be internally powered.

3.6. Allowable Space Envelope: The valve assembly including all components except for the disc shall fit into the allowable space as shown in Appendix B, Figure B-3.

4. VERIFICATION

4.1 Engineering Analysis: Perform an engineering analysis including calculations, assumptions and other supporting data to provide verification that the valve and related components meet the requirements of this specification. Sufficient analysis shall include:

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4.1.1 Valve datasheet.

4.1.2 Stress analysis and supporting information addressing all major components of the valve assembly under loading including, but not limited to, the valve body, bearings, bearing housings, disc, disc connection, shaft, fasteners and welds.

The analysis shall include calculations verifying the ability of the disc to handle maximum differential pressure conditions in the closed position assuming that no support is provided by the valve seal. The analysis shall also include calculations verifying that the maximum sleeve bearing loads are within the design limits and properly distributed along the bearing surfaces.

4.1.3 Actuator sizing calculations which demonstrate the ability of the actuator to rotate the disc at the specified speeds with the valve in any position (including fully closed) under full differential pressure conditions as defined by the chart in Appendix A.

4.1.4 Provide proof by analysis that the disc will not rotate more than 5% of stroke in either direction when maximum pneumatic loads as defined in Appendix A are applied to the disc during a time when there is no power to the actuator motor.

4.2 Pre-Shipment Test(s) and Demonstration(s): The following tests shall be performed by the Contractor:

4.2.1 Hydrostatic Pressure Test: The contractor shall perform a hydrostatic test of the valve body in accordance with ASME B16.34. An ASME dished head or flat plate meeting the requirements of ASME BPVC SEC VIII-D1 shall be welded to the duct ends to contain the hydrostatic test pressure. The dished heads shall have inspection ports for verification of the leak test in section 4.2.3 which follows. Fill, vent, and drain ports for the hydrostatic test shall not be put into the valve body but shall be connected to the heads which will be removed.

Bolting the heads across the valve body for the hydrostatic test is not allowable.

4.2.2 Non-Pressurized Operational Test: An operational test verifying valve actuation of at least 10 cycles, measuring stroke times, and demonstrating proper actuator feedback transducer and limit switch operation. A single cycle is defined as moving from the fully closed position to the fully open position and back to the fully closed position. In addition, the valve disk shall be shown to maintain position at any point between fully open and fully closed with no power to the motor.

4.2.3 Seat Leakage Test: The Contractor shall propose and perform a quantifiable method for verifying that the seat leakage is less than or equal to the leakage rate allowed in Appendix A. The seat leakage test procedure shall adhere to the following guidelines:

The test shall be performed in both directions across the closed valve. The seat shall be tested in the as-installed condition with no lubricant to aid sealing.

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Prior to the seat leakage test, the disc shall be closed using the valve actuator only. The pressure differential shall be as listed in Appendix A. The test media shall be air.

4.3 Pre-Shipment Inspection(s): Contractor shall perform weld inspections in accordance with AWWA C516.

5. PACKAGING

5.1 Preparation for Delivery: The ASME heads used for the hydrostatic test and leak test shall be removed and the duct ends prepared for field welding per section 3.2.1.B of this specification. The Contractor shall provide all preservation, packaging, and packing to ensure safe delivery of the valve and related components to AEDC. The packaging shall be designed to protect the beveled edges of the valve during shipment.

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

Appendix A-1

APPENDIX A

VALVE DATA SHEET

SERVICE

PRESSURE RATING Full Vacuum to 15 PSIG

MEDIA

Air with entrained water and products of jet engine combustion Maximum Flow Condition (preferred direction)

140F, 14.7 PSIA upstream, < 1.7 PSID, 2820 lbm/sec

Maximum Design Differential Pressure 14.5 PSID Both Directions Design Temperature -10°F to +190°F VALVE OPERATION Manual Position Set Point 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 144-inch ID TYPE AWWA C516 Butterfly

END CONNECTIONS

37.5 degree bevel with 1/8 inch land for external welding (see Figure B-1) VALVE LENGTH 42 inch VALVE BODY MATERIAL Carbon Steel

SEAT LEAKAGE

< 5 lbm/min of air at the maximum design differential pressure listed above DUCT SYSTEM I.D. 144.00 inch DUCT SYSTEM O.D. 145.00 inch FAIL SAFE MODE Status Quo ±5%

Appendix A-2

ACTUATOR REQUIREMENTS

ACTUATOR TYPE Electric Motor

VALVE/ACTUATOR STROKE TIME

At Ambient Conditions:

Fully Closed to fully Open in 180 seconds Fully Open to fully Closed in 180 seconds

ACTUATOR TORQUE MARGIN 125% of Maximum Calculated Torque

POWER SUPPLY (Government furnished) 480 VAC 60 Hz 3 phase

CONTROL POWER (Government furnished)

120 VAC 60 Hz 1 Phase

REVERSING STARTER (Government Furnished)

Remote from Actuator

LIMIT SWITCH CONTACTS 16 contacts

POSITION FEEDBACK TRANSDUCER 24VDC, 4 to 20 mA into 250 ohms

ENCLOSURE Weatherproof (WP), NEMA 4X, IP67

ASSEMBLY REQUIREMENTS

VALVE/ACTUATOR ASSEMBLY

ORIENTATION @ INSTALLATION

Valve shaft horizontal Actuator on left looking inlet to outlet

Appendix B-1

APPENDIX B

FIGURES

37.5o

1/2 INCH THICK

DUCT WALL

VALVE BODY WALL

THICKNESS

1/8 INCH

Figure B-1: Weld preparation for valve body

Appendix B-2

Figure B-2: Maximum possible duct forces and moments on valve

+/‐ 3580k ft‐lbs

+/‐ 211k lbs

+/‐ 2800k ft‐lbs

+/‐ 300k lbs

+/‐ 2110k ft‐lbs

+/‐ 211k lbs

Appendix B-3

Figure B-3: Allowable Space Envelope (dimensions shown in inches)

Primary Flow Direction