RFI_Attachment_A_-_Characteristics_Specs_-_Dolores_Project_Valves_and_Actuators_1.pdf

DOLORES PROJECT VALVES AND ACTUATORS

ATTACHMENT A – CHARACTERISTICS/SPECIFICATIONS

I. SCOPE

A. This specification is designed to cover the supply, assembly, and testing of AWWA Class

150B butterfly valves with specified electric actuators attached and adjusted to OEM specifications for direct replacement of existing equipment.

1. The valves shall be designed, manufactured, and tested in accordance with

American Water Works Association Standard ANSI/AWWA C504.

2. Valves shall be proof of design tested in accordance with ANSI/AWWA C504.

3. Valve manufacturer shall have a quality management system that is certified to ISO

9001:2008 by an accredited, certifying body.

4. Motor actuators shall be furnished in accordance with AWWA C542 for Power

Actuators and factory tested on the production valve. The motor unit shall be mounted to a self-locking traveling nut actuator with characterized closure and externally adjustable closed stop. The motor actuator assembly shall be designed for open/close service with a minimum operating time as indicated. Electrical operation shall include Local-Off-Remote selector switch, local Open/Close push buttons and position indication lamps.

II. QUALITY ASSURANCE

A. The Vendor shall assemble, adjust, and test the valves and actuators in accordance with

OEM instructions prior to delivery. Test reports confirming the calibration of all limit switches, torque switches, and operation shall be supplied with delivery.

B. All valves shall be hydrostatic and leak tested. The leak test shall be performed at a differential pressure of 250psig with the disc in the closed position. With the disc in a slightly open position, internal hydrostatic pressure equal to 500psig shall be applied to the inside of the valve body for five (5) minutes.

III. BUTTERFLY VALVES

A. General

1. Valves shall comply with the applicable requirements of the latest revision of AWWA

Standard C504.

2. Valves shall be suitable for providing bubble tight shutoff in either direction in ordinary non-shock water service.

3. Valves shall be rubber seated, 90° disc rotation (1/4 turn), short body with flanged joint ends.

4. Valves shall be bi-directional, capable of either open left (standard) or open right (non-standard).

B. Connections

1. Connections shall be flanged and conform with ANSI B16.1 for Class 125 iron flanges.

Flanges shall be flat faced.

C. Design

1. Valve shafts shall be of the through-type with dimensions in accordance with AWWA

C504.

2. Valve discs shall be of the solid type without external ribs or vanes to obstruct flow.

Disc shall be furnished with a 316 stainless steel seating edge to mate with the rubber seat.

3. The seat shall be vulcanized and bonded into a recessed cavity in the valve body.

4. Valves shall be furnished with self-lubricating bearings to provide continuous low-friction, maintenance-free operation.

5. Thrust bearings shall be provided.

6. Shaft seals shall be of the V-type and shall be replaceable without removal of the valve from the line or the shaft from the valve.

7. Valve body shell thickness shall be in accordance with AWWA C504.

D. Materials

1. Body: Class 150B valve bodies shall be ASTM A126, Class B gray iron or ASTM A536

Grade 65-45-12 ductile iron.

2. Disc: Valve disc shall be ASTM A536 Grade 65-45-12 ductile iron.

3. Shafts: Shafts shall be ASTM A276 type 304, or ASTM A564, Type 630 Stainless Steel.

4. Seat: Resilient seat shall be Buna-N.

5. Hardware: All seat retaining hardware shall be Type 316 stainless steel.

6. Bearings: PTFE with stainless steel backing.

7. Shaft Seals: Buna-N

E. Painting

1. All surfaces of the valve interior shall be clean, dry and free from grease before painting. The valve interior and exterior, except for disc edge, rubber seat and finished portions shall be evenly coated with an NSF61 approved 2-part liquid epoxy. Minimum dry film thickness shall be 8 Mils minimum.

IV. ACTUATORS

A. General

1. Actuators shall be designed for valve operation to ensure proper function in accordance with EN 15714-2:2010 electric actuators for industrial valves - basic requirements. Actuators shall be designed for ON-OFF, short-time duty (S2-15min) respectively Class A and B according to EN 15714-2.

2. Actuator shall have a design life of 10,000 OPEN-CLOSE-OPEN cycles, each consisting of 30 turns per sense of rotation and must be suitable for operating in any mounting position. Actuator design must provide simple setting, testing, maintenance and repair.

3. Actuator settings shall be performed non-intrusively via pushbuttons at motor control without special tools or instruments (e.g. battery backed setting tool). A wireless

Bluetooth interface shall be available. Microsoft Windows based software running on a conventional computer shall be available to allow actuator set-up and diagnoses.

4. Electrical connection of actuators shall be multi-pin, plug-and-socket connector, allowing quick disconnection in case of maintenance or repair. In order to prevent loss of screws during commissioning or maintenance, all covers shall be fixed with captive screws. In order to minimize the amount of spare parts required, parts such as covers, plug and sockets, parts must be interchangeable throughout all model sizes.

5. Torque-transmitting housings must be made of cast iron, except motor housing. No plastic parts of any type shall be used, except for electric / electronic components, operating knobs / levers, indicator mechanism and sealing elements as far as applicable.

6. Depending on valve application, actuators shall be self-locking. Self-locking shall remain active if actuator is switched to hand-operation-mode. For non-self-locking actuators with high output speeds a mechanical anti-back drive device shall be provided attached to the actuator.

7. Valve mounting dimensions shall be according to ISO 5210 with use of a plug sleeve connection adapting to valve shaft. For rising stem applications, actuator design must allow actuator removal from output drive without disturbing the valve function.

B. Electric Motors

1. Motors must be suitable for operating at 3 phase power supply voltage of 480 Volt

AC, 60Hz and shall be specifically designed for valve-actuator operation, characterized by high starting torque, low stall torque and low inertia. Motors shall be totally enclosed non ventilated type (TENV). Motor housings and covers to be made of sea water resistant aluminum. Motor-insulation must be in accordance with IEC 60085 Class F (155° C).

Motors must be protected by 3 thermal monitoring devices, which are embedded in motor windings. Motor connections shall be internal by means of plug and socket.

2. Motors must be totally separated from lubricant-filled gearing of actuator, allowing replacement of motor without loss of lubricant regardless of mounting position. Motors shall have a dog coupling as mechanical connection to actuators worm shaft.

3. Actuator motors must develop full torque when power is turned on. All motors shall be of high starting torque type to facilitate 'unseating' of the valve. Each motor shall have a rating plate marked in accordance with IEC 60034-1 as far as applicable.

C. Sizing

1. One actuator size (same outside dimensions) shall be available covering output speeds from 4 to 180 rpm for a given torque range, to avoid over sizing and unnecessary weight load on valve stem, flange and yoke. An increase of actuator size caused by higher actuator output speed is not acceptable to avoid weight over-sizing of actuators.

Actuators must be selected to provide sufficient torque required for safe valve operation.

Actuator output torque must be available at 90% of nominal voltage.

2. Actuator shall be capable of opening and closing the valve against full differential pressure within specified time per valve.

D. Limit and Torque Monitoring

1. No battery backed limit sensing shall be used to avoid actuator malfunction in case of power failure. Actuators shall have a hall sensor principle based absolute encoder for limit sensing with a resolution of 3° or better. Actuator shall not be equipped with a battery.

2. Torque sensing shall be of mechanical sliding worm principle with torque values independently settable for 'OPEN' and 'CLOSE' direction. No electronic torque sensing derived from motor current or piezo-electric torque sensing at worm shaft is acceptable.

Torque setting shall be possible for 40% to 100% of rated torque.

E. Motor and Local Controls

1. Integral motor controls shall be microprocessor based and include mechanically and electrically interlocked reversing contactors for ON-OFF, short-time duty S2-15min with hard wired signals OPEN-STOP-CLOSE, including a 4-20mA output signal, internally powered. Detailed wiring diagram shall be supplied with submittal documents.

2. Local controls shall consist of motor controls, push buttons OPEN-STOP–CLOSE–

RESET, lockable selector switches LOCAL-OFF-REMOTE and a wireless Bluetooth interface with separate indication showing wireless connection as active, as well as LCD graphic display clearly visible under all lighting conditions with plain text and in world languages, diagnosis symbols, graphs. Five indication lights, available in different color codes, showing status information such as end position open/close, torque fault in both directions and motor protection tripped.

3. Local controls shall be electrically attached to actuator via plug and socket connection. It shall be possible to re-position local controls at every 90°, so that push buttons and indication lights will face the operator.

4. In addition to this, actuator must provide a dedicated fault signal if there is a phase failure, motor protection tripped and/or high torque in OPEN/CLOSE direction or if hand wheel is engaged.

5. All control signals, communication signals as well as main power supply must be wired to a multi pin plug and socket for customer connection. Terminal compartment shall provide sufficient space to accommodate the possible maximum number of incoming wires. A minimum of three cable entries must be provided for motor power cable and digital/analog inputs and outputs.

6. Each actuator shall provide an adequately sized internal and external connection for grounding.

F. Anti-Condensation Heater

1. In order to prevent condensation, a heater must be installed inside the actuator, suitable for continuous operation. Actuator must provide an alarm signal in case of failure of anti-condensation heater.

G. Enclosures

1. Protection class of actuator, including motor, shall be IP 68 (NEMA 4X/6P), according to EN 60529 against submersion up to 8 m head of water for at least 96 hours. During submersion it must be possible to operate the actuator at least 10 times.

H. Hand Wheel

1. Actuators must be equipped with a hand wheel for manual operation. Clockwise operation of hand wheel shall cause clockwise movement of output drive. Hand wheel shall be clearly marked with an arrow and the word 'CLOSE'.

2. Hand wheel engagement shall be of spring-loaded, push-mechanism type and required manual declutching. Actuator must provide a switch signal when in manual mode.

3. Under manual operation, hand wheel shall drive the worm shaft. Self-locking shall be maintained in hand operation. Motor must be disengaged during manual operation. Hand wheel shall automatically disengage when the electric motor is energized.

4. Hand wheel must be sized allowing easy manual operation of output drive. The over torque indication shall be active in manual operation as well as motor operation, thus allowing a signal to be provided when the set-torque has been reached.

I. Bearings and Gears

1. Bearings shall be of antifriction or self-lubricating type. Bearings shall not require any maintenance between general overhauls. Power gears shall be made from heat treated steel. Worm-wheels shall be made of bronze material. Actuator gear housing shall be filled with an adequate quantity of lubricant. Re-lubrication between general overhauls shall not be required.

J. Noise Level

1. Under all operating conditions the noise level of actuators shall not exceed 75 dB(A) at 1 m.

K. Nameplates

1. Two nameplates, made of aluminum, shall be attached to each actuator, one on the motor housing, showing all relevant motor data, one on the actuator housing showing all relevant actuator data. Special information, such as valve tag no., shall be shown if required. Nameplates shall be securely fixed to actuator and motor, so that they cannot be removed or scratched off during shipment, installation, operation or maintenance.

L. Painting and corrosion protection

1. Actuator corrosion protection shall fulfill the requirements of EN ISO 12944-2, classification of environments C4 with a specified salt spray test of 720h. Actuator painting must be performed in such a way, that no corrosion takes place under ambient conditions as specified. All outside screws or bolts shall be made of stainless steel (A2).

Actuators shall be corrosion protected with a primer coating and a two-layer powder coating consisting of an epoxy coating and a polyurethane top coating with a total film thickness of at least 140µm. Final color shall be silver grey similar to RAL 7037.

M. Inspection and Testing at Manufacturer's work

1. Each actuator shall be factory tested. Tests shall be performed in accordance with

IEC or NEMA standards as far as applicable. A final inspection record shall be supplied with each actuator showing general actuator data, nominal current, no load current, starting current, power factor at rated torque, output speed, torque setting, limit setting

(turns/stroke), high voltage test, functional test (including all options) and visual test.

V. GEARBOXES

A. General

1. Worm gearboxes shall be specifically designed for butterfly valves and damper operation and shall meet the torque/lifetime requirements of EN 15714-2 (electric actuators for industrial valves – basic requirements).

2. Worm gearboxes shall be designed to be operated either manually or electrically in combination with multi-turn actuators. Generally, it shall be possible to install a motor on a manually operated valve at a later stage without replacing the complete gearbox.

3. Worm gearboxes shall be available for output torques up to 700,000 Nm.

4. The gearboxes shall be equipped with worm wheels.

5. Spindle or scotch - yoke type gearboxes are not acceptable.

B. Design

1. The gearboxes shall be self-locking.

2. The gearboxes shall have a worm wheel and worm shaft, including adjustable mechanical end stops.

3. If required, worm gearboxes shall be equipped with a primary planetary gearing to reduce input torque.

4. The gearbox housing shall be made of cast iron. Aluminum housing material (torque transmitting parts) is not acceptable.

5. The gearbox housing shall be filled with grease to guarantee adequate lubrication in any mounting position and a long service life.

6. Special self-lubricating bearings shall be provided to accept radial forces on the worm shaft.

7. A thrust bearing shall carry the resulting axial load.

9. For motor operation, the gearboxes shall be capable of withstanding actuator tripping torque without damage.

C. Valve Position Indication

1. An adjustable mechanical pointer to show the valve position shall be available.

D. Enclosure

1. Enclosure protection shall be at least IP68, according to EN 60529.

2. Worm gearboxes shall be sealed by radial seals or O-rings.

E. Coupling / Valve Attachment

1. A removable splined coupling shall be supplied by the gearbox manufacturer allowing easy machining of the bore to suit the valve shaft.

2. The gearbox valve attachment dimensions shall be according to EN ISO 5211.

F. End Stop Principle

1. The adjustable mechanical end stop shall be designed as travelling nut to protect the gearbox housing / valve stem from excessive force. The design shall guarantee a defined stop when reaching the end of travel (valve is closed). The end stop shall be equipped with safety wedge discs to guarantee a mechanical stop block principle.

2. The end stop design shall accept the input torques as axial forces within the worm shaft, the load not being transmitted to the gearbox output / valve stem.

3. Travel limitation with stop screws (end stop screws as used for segment or quadrant type) placed in the gearbox housing shall not be permitted, as protection against excessive torque cannot be guaranteed.

4. The mechanical end stop shall be easily adjustable during commissioning and maintenance work on site to guarantee proper seating of the valve during operation.

Swing angle shall be set in accordance with OEM recommendations.

G. Nameplate

1. Nameplate shall be made of stainless steel showing all relevant gearbox data. The name plate shall be securely fixed to the gearbox, so that it cannot be removed or scratched off during shipment, installation, operation or maintenance.

H. Painting and Corrosion Protection

1. Corrosion protection shall fulfil the requirements of salt spray tests in accordance with DIN 50021.

2. Gearbox painting must be performed in such a way to avoid corrosion under ambient conditions as specified. All outside screws or bolts shall be with metallic surface protection or made of stainless steel (A2). Use of stickers are also permitted if qualified.

3. For finish painting high quality powder coating system shall be used.

VI. SELECTION OF PRODUCTS

A. Individual components shall meet all product requirements of this specification.

B. Butterfly valves shall be sourced from a single manufacturer.

C. Electric actuators, controllers, and gearboxes shall be supplied by the same manufacturer.

D. Motor actuators and controllers used in each location shall be identical and interchangeable.

VII. ASSEMBLY

A. The Vendor shall assemble valves, gearboxes, actuators and controllers and make all necessary adjustments to limit and torque switches to ensure proper fitment and operation before delivery.

B. Valves, gearboxes, actuators, and controllers shall be delivered as complete assemblies or as complete as can be safely transported for shipping.

VIII. TESTING

A. Each valve assembly shall be verified for correct operation and adjustment prior to shipment, to be documented and delivered