Atch 1 -15571-20-002 Motorized 156-Inch Diameter Butterfly Valve Spec.pdf

15571-20-002

Spec No. 15571-20-002 30 September 2020

ITEM SPECIFICATION FOR:

MOTORIZED 156-INCH DIAMETER

BUTTERFLY VALVE ASSEMBLY

ARNOLD ENGINEERING DEVELOPMENT COMPLEX

ARNOLD AIR FORCE BASE, TN 37389

NOT SENSITIVE

IRA-5312

IRA-5312 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 Interface Requirements

3.5 Studs and Nuts

3.7 Allowable Space Envelope

4. SUBMITTALS

4.1 Engineering Analysis

5. VERIFICATION

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

IRA-5312 Table of Contents - 2

Appendix A – Valve Data Sheet

Appendix B – Support and Mounting Location

Appendix C – Gearbox and Keyway Details

Appendix D – Reference Photo

IRA-5312 Page - 1

1. SCOPE

1.1 This specification establishes the performance, design, manufacture and verification requirements for a 156-inch diameter steel flat-faced flanged butterfly valve assembly per AWWA C516. Valve assembly shall interface with existing electric motor and gearbox actuator and controls. Valve shall include companion flanges with prepped weld ends for installation into the existing duct.

2. APPLICABLE DOCUMENTS

2.1 Government Documents:

2.1.1 Statement of Work 15571-20-001.

2.2 Non-Government Documents:

2.2.1 American National Standards Institute (ANSI):

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

2.2.2 American Society of Mechanical Engineers (ASME):

A. ASME B1.1-19 Unified Inch Screw Threads.

B. ASME B16.34-17 Valves - Flanged, Threaded, and Welding End.

C. ASME B18.2.1-13 Square, Hex, Heavy Hex, and Askew Head Bolts and Hex, Heavy Hex, Hex Flange, Lobed Head and Lag Screws.

D. ASME B18.2.2-15 Nuts for General Applications: Machine Screw Nuts, Hex, Square, Hex Flange, and Coupling Nuts.

E. ASME BPVC SEC II-D-19 Section II-D Properties – Materials.

F. ASME BPVC SEC VIII-1-19 Section VIII Division1 Rules for Construction of Pressure Vessels.

2.2.3 American Society for Testing and Materials (ASTM):

A. ASTM A193-20 Alloy-Steel and Stainless Steel Bolting for High Temperature or High Pressure Service and Other Special Purpose Applications.

IRA-5312 Page - 2

B. ASTM A194-20 Carbon Steel, Alloy Steel, and Stainless Steel Nuts for Bolts for High Pressure or High Temperature Service, or Both.

2.2.4 American Water Works Association

A. AWWA C207-18 Steel Pipe Flanges for Waterworks Service, Sizes 4 in. Through 144 in.

B. AWWA C516-14 large-Diameter Rubber-Seated Butterfly Valves, Sizes 78 in. and Larger.

3. REQUIREMENTS

3.1 General: Valve assembly shall consist of valve, valve flanges, companion flanges, and related components, shall be designed, fabricated, assembled, tested and verified in accordance with the requirements herein.

3.2 Construction: The valve shall be designed, constructed, and inspected 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.

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.

IRA-5312 Page - 3

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 reference 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.

B. Design for a 25-year life with a mean time between failures (MTBF) 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 (MTTR) valve seal not greater than 24 hours.

3.2.9 Transportability:

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

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

Mark the lugs with their respective load capacity in lbs.

C. Valve shall be shipped with companion flanges attached to each flange of the valve with studs and nuts, as read for installation

3.2.10 Nameplates & Markings:

A. Valve actuator and valve body shall have the respective manufacture’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, temperature rating, and flow capacity (Cv) on the valve plate.

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

IRA-5312 Page - 4

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, designed, and inspected per AWWA C516. The valve body components shall be Carbon Steel in accordance with ASME SEC II-D, as in Appendix – A, Valve Data Sheet.

B. The ends of the valve body shall be flanged with Class D flanges, in accordance with AWWA C207. The accompanying companion flange shall be Class D in accordance with AWWA C207.

C. The valve body shall be oriented with the valve shaft horizontal and shall rest on supports as per Appendix B. Supports shall be sized to accommodate full weight of valve assembly while matching existing bolt hole locations shown in Appendix B.

D. Principal design stresses shall not exceed one-fifth of the ultimate or one-third of the yield strength of the materials used when the valve is operating under the maximum conditions for temperature and pressure.

3.3.2 Valve Disc:

A. Valve disc shall be fully capable of bidirectional sealing, and provide adequate bidirectional flow. Allowable leakage and flow requirements are listed in Appendix A.

B. Material: Shall be Carbon Steel in accordance with ASME SEC II-D, as shown in Appendix – A, Valve Data Sheet.

C. Disc to shaft connection shall make 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 pins or keys. All pins, keys, and other materials used to secure disc to shaft shall be mechanically secured to prevent entry into flow stream.

E. Roll pin connections are not acceptable.

3.3.3 Valve Seat/Seal:

A. The seal material shall be rubber per AWWA C516 and replaceable without having to remove the valve from the duct.

B. The valve shall have a stainless steel seat.

IRA-5312 Page - 5

C. The seal 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.

F. Roll pin connections are not acceptable.

3.3.4 Valve Shaft/Stem:

A. Material shall be in accordance with ASME SEC II-D. The Contractor shall design the shaft with a hardness with respect to the bearing material to prevent galling.

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 shall not be permitted.

C. Bearings shall be designed so as not to require heating or cooling.

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.

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:

A. If used the design of the bushing and bearings shall prevent lubricant from entering or coming in contact with the flowing medium.

B. Any lubrication fittings shall be externally accessible for maintenance.

IRA-5312 Page - 6

3.4 Interface Requirements:

3.4.1 Electric Motor and Actuator:

A. The Contractor shall provide valve with valve shaft/stem compatible with existing Auma SA 14.1-108B Actuator and existing Auma GS 400 gear box, as per Appendix C. Factory Output Torque are in Appendix - A, Actuator Requirements.

3.4.2 Controls and Instrumentation Requirements:

A. The Valve shall be compatible with all existing controls and instrumentation on current actuator and shall meet the existing actuator requirements, see Appendix A.

B. The Valve shall function as in current installation as an open/close butterfly valve.

3.5 Studs and Nuts Requirements

3.5.1 Studs and Nuts

A. ASTM A193 B7 Studs per ASME B18.2.1.

B. ASTM A194 2H Heavy Hex Nuts per ASME B18.2.2.

C. ASME B1.1 Coarse Thread Up Thru 1 inch, 8 TPI greater than 1 inch.

D. Diameter and number of studs to be determined by manufacturer.

3.6 Allowable Space Envelope:

3.6.1 Valve assembly shall fit in a pit with a width of no more than 140 Inches from the center line of the ducting.

3.6.2 Valve assembly height shall fit in the pit with no more than 96 inches above and below the center line of the ducting.

3.6.3 Lay length of the valve including companion flanges shall be no longer than 144 inches.

3.6.4 Reference photo of existing valve in Appendix D.

4. SUBMITTALS

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. Analysis shall include:

IRA-5312 Page - 7

4.1.1 Valve Data Sheet.

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 housing, disc, disc connections, 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 bearing loads are within the design limits and properly distributed along the bearing surfaces.

4.1.3 Disc and shaft sizing calculations which demonstrate the ability of the actuator to rotate the disc at the specified speeds with the valve in any position under full differential pressure conditions as defined by the chart in Appendix A.

4.1.4 Drawings to be provided for Government approval:

A. Fabrication and assembly drawings for the flanged valve.

B. Fabrication drawing for the mating flanges.

C. Assembly drawing for the valve assembly.

D. Bills of Material, details, and assembly information for the end user to replace parts or repair the valve and components.

E. Certified valve assembly weight and center of gravity diagram.

4.1.5 Material Certification Documentation.

4.1.6 Welding WPS, PQR, and welder qualifications.

5. VERIFICATION

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

5.1.1 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 blind flange meeting the requirements of ASME BPVC SEC VIII-D1 shall be attached to the duct ends to contain the hydrostatic test pressure. Fill, vent, and drain ports for the hydrostatic test shall not be put into the valve body but shall be connected to the heads, or flanges, which will be removed. Bolting the heads across the valve body for the hydrostatic test shall not be permitted.

5.1.2 Non-Pressurized Operational Test; As per AWWA C516, Valve shall be shop-operated three full cycles of close-open-close under no-flow, no pressurized conditions, with approved actuator and gearbox. During test output torque of test

IRA-5312 Page - 8 actuator shall be recorded. The required torque shall not exceed 70% of factory torque of current actuator and gearbox, as listed in Appendix A.

5.1.3 Seat Leakage Test: The Contractor shall perform the seat leakage testing with allowable leakage found in Appendix A. The seat leakage test procedure shall adhere to the following guidelines:

A. 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, or other chemical compounds to aid sealing.

B. Prior to the seat leakage test, the disc shall be closed and the output torque recorded. The pressure differential across the disc is listed in Appendix A. The test media shall be air.

C. The test duration shall be at least 5 min, both directions.

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

6. PACKAGING

6.1 Preparation for Delivery: The Contractor shall provide all preservation, packaging, and packing to ensure safe delivery of the valve and related components to Arnold Air Force Base, TN.

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

7. NOTES: Not Applicable

IRA-5312 Appendix A - 1

APPENDIX A

VALVE DATA SHEET

SERVICE

DESIGN PRESSURE Full Vacuum to 20.0 PSI MEDIA Air with entrained water and products of jet engine combustion Maximum Flow Condition With Valve Fully Open (Preferred Direction)

140F, 14.7 PSIA Upstream ≤1.7 PSID, 1550 lbm/sec

Maximum Design Differential Pressure 20.0 PSID, Bidirectional Design Temperature -10°F to +200°F VALVE OPERATION Open/Close Valve for Plant

Configuration ENVIROMENTAL CONDITIONS Outside Installation/Unsheltered In Open

Pit Temperature -10°F to +110°F Relative Humidity 20 to 100% Barometric Pressure 13.7 to 20.0 PSIA

VALVE REQUIREMENTS

VALVE SIZE 156-inch ID VALVE TYPE AWWA C516 Butterfly END CONDITIONS Consistent with AWWA C207 Flanged, with Companion Flanges attached, and prepared with 37.5 degree bevel with 1/8 inch land for external welding on duct VALVE BODY MATERIAL ASME SEC II-D Carbon Steel VALVE DISC MATERIAL ASME SEC II-D Carbon Steel SEAT LEAKAGE In Accordance with FCI 70-2 Class V

Bidirectional DUCT SYSTEM I.D. 156 Inch DUCT SYSTEM O.D. 157.25 Inch

IRA-5312 Appendix A - 2

EXISTING ACTUATOR SPECIFICATIONS

ACTUATOR TYPE AUMA SA 14.1-108B

GEARBOX AUMA GS 400

MAX ACTUATOR ASSEMBLY OUTPUT

TORQUE

122,210 ft-lbs

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

CURRENT ROTATION Actuator rotates counterclockwise to open

CONTROL REQUIREMENTS

Stroke Time 3-5 Minutes Consecutive Open – Close – Open Cycles

ASSEMBLY REQUIREMENTS

VALVE/ACTUATOR ASSEMBLY

ORIENTATION @ INSTALLATION

Valve Shaft Horizontal Actuator on Left while looking inlet to outlet Valve installed on Horizontal Ducting

END OF APPENDIX A

IRA-5312 Appendix B - 1

APPENDIX B

SUPPORT AND MOUNTING LOCATION

Figure B.1 - Support and Mounting Location

END OF APPENDIX B

IRA-5312 Appendix C - 1

APPENDIX C

GEARBOX AND KEYWAY DETAILS

Figure C.1 - Existing Shaft Keyway Dimensions

IRA-5312 Appendix C - 2

Figure C.2 -Existing Gearbox Cut sheet

IRA-5312 Appendix C - 3

Figure C.3 -Existing Gearbox Cut sheet

END OF APPENDIX C

IRA-5312 Appendix D - 1

APPENDIX D

REFERENCE PHOTO

END OF SPECIFICATION AND APPENDICES