Spec_ElectricActuators_RiverGt_Final.pdf.crdownload

MWW Specification 2603

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“YES” and “NO” questions displayed on the LCD. “YES” is signaled by using the OPEN switch and “NO” by using the CLOSE switch, as indicated adjacent to the switches. A configurable password option shall be available to prevent unauthorized changes. Actuator to be configured with primary power and shall be able to connect to SCADA system via 4-20 mA signal.

C. Actuators shall be designed to open and close the existing sluice gates through controls from the actuator as well as SCADA control from a remote location. Actuators shall be able to open and close the existing sluice gates, and stop during the opening and closing to allow gates to be partially open with a percent indication of the sluice gate position. Actuators shall include pedestal mounts, angle gears, and components necessary for mounting the actuator on the existing valve.

1.04 SUBMITTALS

A. Shop Drawings:

1. Product technical data will be provided to confirm the details required in the specification, including but not limited to:

a. Submit recommended speed ranges for each valve size in the Shop Drawing. Coordinate opening and closing speeds during submittal review. Owner and Engineer will select initial setting per valve.

b. Submit recommended actuator mounting for each valve and location in the Shop

Drawing. Coordinate valve and actuator orientation, to promote readability and handwheel operation during submittal review. Owner and Engineer will confirm orientation per valve.

2. Drawings shall include a wiring diagram for each electrically operated actuator and the electrical control equipment.

3. Certifications and Statements:

a. Acknowledgement that products submitted meet requirements of standards referenced.

b. Manufacturer's installation instructions.

4. Test reports.

B. Operation and Maintenance Manuals:

1. Submit preliminary operation and maintenance instructions with the shop drawings.

2. Submit final operation and maintenance instructions before requesting payment for this section of work.

1.05 QUALITY ASSURANCE

A. Electric Actuators shall be fully compliant with AWWA C542 and meet the project conditions described in this specification.

B. All non-metallic materials and coatings that might contact water inside process valves shall be certified as suitable Drinking Water System Components by NSF/ANSI 61.

C. Manufacturers of valves and actuators shall have a minimum of 10 years of documented experience in production of the specified equipment type and size and used in water or wastewater service. Submit evidence as required in call for bids or upon request.

1. Supplier must have local support within a 45 mile radius of facility.

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1.06 DELIVERY STORAGE AND HANDLING

A. All equipment shall be delivered in crates to provide protection during transit and job storage.

Cover all pipe and electrical connection openings with suitable coverings, caps or plugs.

PART 2 - PRODUCTS

2.01 INTELLIGENT ELECTRIC ACTUATORS

A. Intelligent Electric Actuators shall be Limitorque MX Series B or approved equal.

B. Actuators shall be configured as required to provide for multi-turn operation and be coupled with gearboxes as required to obtain the speed and operating torque as required for the valve.

Gearboxes between the valve and actuator shall be heavy duty, totally enclosed, with sealed bearings, operating in a lubricant.

C. Valve functionality and operation shall meet the goals Process and Instrumentation Diagrams.

D. Torque capacity shall be determined in coordination with the valve manufacturer and be at least

150 percent of the maximum torque needed by each valve.

E. Actuators shall be O-ring sealed, watertight to standards NEMA 4X submersible to IP68.

Controls shall be non-intrusive and sealed for life.

F. Housing shall be cast aluminum with powder coat finish to resist corrosion in extreme environments. The coating system shall be suitable for an ASTM B117 salt spray test of 1500 hours. External fasteners shall be stainless steel or high-strength carbon steel that has been chromate-hexavalent coated, and then top coated with a high-strength, high-endurance polymer.

G. Enclosure shall be double-sealed with a separate, water-tight terminal compartment.

1. The terminal compartment shall include screw-type terminals, three for power and 54 for control, for site connections. Three conduit entries, available as: (2) - 1.25" NPT (M32) and

(1)-1.5" NPT (M40) shall be located in the terminal compartment.

2. Terminals shall be included to connect the electronic controls package, including display, to a back-up 24 VDC power source for use with commissioning and for controls feedback during loss of primary power.

H. Power supply shall be 480 Volt, 3-Phase, 60 Hertz. System shall detect phase errors and protect the motor from damage.

I. Control of the actuator shall be by direct wiring. Control circuits will be 24VDC. Unless otherwise noted, provide four-wire control for open, close, and stop.

J. Configuration of the actuators shall be via wireless signal using a HART communication protocol hand-held device and the selector switches or pushbuttons on the actuator.

K. Duty Cycle shall be minimum 15 minutes.

L. Open-closed valve actuators shall be capable of 60 starts per hour. Modulating actuators shall contain proportional control unit and be capable of 1200 starts per hour.

M. Drive motor shall be of sufficient size to open or close the valve against the maximum differential pressure when voltage to the motor terminals is a maximum of 90 percent of the nameplate rating.

The drive motor shall be specifically designed for operator service.

1. Drive motor shall be of the squirrel cage induction type and shall be of totally enclosed non-ventilated (TENV) construction with permanently lubricated ball bearings.

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2. Motor shall be thermally protected. The actuator shall include a thermistor and provide feedback on current temperature of motor windings to prevent overload conditions as well as provide feedback of possible open or shorted thermal feedback failures. The use of thermostats for motor protection are not acceptable.

3. Motor shall be capable of starting against the rated load.

4. Motor nameplate shall be in accordance with NEMA standard MG-1. Motor housing shall be cast aluminum or cast iron.

5. Motor shall be capable of operating in any orientation. Motor shall be mounted such that the motor shaft does not penetrate the gearbox allowing motor changeout without loss of gearbox lubricant.

6. Motor shall be directly connected to worm shaft.

N. Reversing starters shall be integral with actuator and shall be solid-state starters for modulating service. Electro-mechanical reversing starters shall be acceptable for open-close service and shall be mechanically and electrically interlocked.

O. Actuators shall have power gearing consisting of hardened steel or alloy steel gears and alloy bronze worm gear, all grease or oil bath lubricated, designed for 100 percent overload, and effectively sealed against entrance of foreign matter. Nonmetallic or aluminum gearing shall not be allowed. Support rotating shafts with anti-friction bearings. Actuators shall be lubricated for the life of the product. Actuator gear set shall be locking.

P. Actuator mechanism shall be constructed to permit field changes of valve rotation speed by the internal control system.

Q. Standard AWWA 2” operator nut shall be permanently attached for manual operation in lieu of handwheel. The nut for valves shall require a maximum input force of 80 pounds on the rim and handle for seating, unseating, and running load. Include a positive declutch mechanism to engage and disengage nut. Declutch lever shall include provision to be padlocked. Operating nut shall not rotate during motor operation. Inoperable motor shall not prevent manual operation. Include an arrow showing direction of opening and the word "OPEN" around nut.

1. Actuator shall include a removable torque or thrust bushing to mate with the valve shaft.

R. Actuators shall use absolute position encoders that don’t require battery back-up. The encoders measure valve position at all times, including both motor and handwheel operations, with or without power present.

1. Multi-turn actuator shall use uses an 18-bit resolution encoder, with redundant circuits which cause 100% repeatability.

2. All actuators shall have a built-in self-test that enables each actuator to function reliably with built-in redundancy and without the need for an internal battery.

S. Torque sensing shall be highly reliable and predictable, by sensing torque electronically for use in valve control, overload protection and torque trending. Electromechanical torque switches will not be allowed.

T. Actuators shall include a boost function to prevent torque trip during initial valve unseating, and a

Jammed Valve Protection feature will de-energize the motor if the output torque requirement exceeds the boost torque.

U. Actuators shall permit operational speeds in Open and Closed directions to be set independently.

Actuators shall also include a Two-Speed-Timer extend the actuator travelling time in opening and/or closing direction.

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V. Electronic Control Module shall include an LCD display that shows actuator status and valve position, as well as real-time torque graphs, alarm and event logs. Actuators shall include a time-stamped data log of local and remote move commands as well as events and alarms. The event and alarm list shall be configurable and store thousands of historical actions. The data logging system shall be backed up by an internal battery with an operating life of more than 10 years.

1. Actuators shall incorporate advanced diagnostics that provide process visibility and control.

Diagnostic system shall be capable of alerting operators when alarm and event conditions occur. The diagnostics system shall track the actuator environment and performance through a sophisticated set of sensors. Any deviation of voltage, operation, torque, and vibration from specified ranges can be reported. System shall allow adjusting configurations and scheduling proactive maintenance, when necessary, before equipment failures occur.

2. All Diagnostic information shall be viewable from the LCD screen. The need to connect a portable tool to a computer to analyze data is not acceptable. The actuator shall monitor and store all diagnostic data regardless if a user is utilizing that feature.

W. Include 4-20 mA position feedback device.

X. Include four latching status contacts for remote indication of valve position or status. Include four additional contacts that may be configured.

Y. Local control selector switches or pushbuttons shall open, stop, and close the actuator and select remote or local condition. Switches shall be magnetically coupled, solid-state Hall effect devices.

Local control switches shall be designed to make set-up and commissioning simple, enabling easy selection of options and movement through the menus.

Z. Local Indication Features. The following functions shall be possible by pilot lights on the housing.

1. Full open light (Red).

2. Full close light (Green)

3. Back-lit LCD information screen.

AA. Performance Testing: Each actuator shall be performance-tested according to AWWA C542 prior to shipment. If any component of the actuator fails during testing, the malfunction shall be corrected or repaired as required and the actuator retested.

BB. The actuator shall be equipped with Bluetooth® Low Energy (LE) and meet at least the

Bluetooth® 4.0 standard for lower power consumption. Bluetooth® shall be available which permits a User to download or upload configuration routines via a PC or tablet. The initial pairing of the Bluetooth® communication link shall be passkey protected by a user configurable passkey at the actuator. A visible blue LED in the controls LCD window shall be included to signify an active Bluetooth® link to the actuator is established.

CC. Protections

1. Standard Alarms and Warnings shall be available in the actuator for indication of a failure of normal operation at the LCD. These alarms should be non-configurable for:

a. Close and Open Overtorque, Motor Overtemp, Valve Jammed, Lost Phase

b. Encoder Fault, Knob Fault, Memory Fault, Contactor Fault, Boards Comm Loss

c. Encoder Warning, RTC Battery Low, Starts/Hr Exceeded, Vibration Exceeded

2. Deviation warnings shall be available to alert of potential issues before faults occur by monitoring changes in the units operation when compared to a reference value. Deviation levels shall be configurable for LCD display and/or relay feedback and include:

a. Torque

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b. End position

c. Vibration

3. High Level Warnings shall be available to alert of potential issues before faults occur by monitoring changes in the unit’s operation by crossing a configured threshold. High Levels shall be configurable for LCD display and/or relay feedback and include:

a. Torque

b. Vibration

c. Motor Temp

d. Starts per hour

e. Drive sleeve turns

f. Stars open and starts close

g. Move-to hunting counts

h. Service time

4. A Phase Correction circuit shall be included to correct motor rotation faults caused by incorrect site wiring. The phase correction circuit shall also detect the loss of a phase and disable operation to prevent motor damage. The monitor relay shall trip and an error message shall be displayed on the LCD screen when loss of phase occurs and indicate the fault for

Remote operation

5. A dedicated circuit to prevent undesired valve operation in the event of an internal circuit fault or erratic command signal shall be included. A single point failure will not result in erratic actuator movement. An open or short-circuit in the internal circuit board logic shall not energize the motor contactor, nor shall a single fused control relay contact fail to deenergize the motor contactor. The command inputs shall be optically coupled and require a pulse width of at least 250 ms to 350 ms to turn on or off. In the event of an internal circuit fault, an alarm shall be signaled by tripping the Monitor Relay and through LCD indication.

2.02 NAMEPLATES

A. Manufacturer nameplates shall be permanently attached to every actuator, showing manufacturer name, equipment type (model or style), and size. Actuator nameplates shall include all pertinent data to identify the unique features of each unit. All nameplates shall be made of stainless steel.

PART 3 - EXECUTION

3.01 PROTECTION AND DELIVERY

A. Manufacturer will prepare all equipment for safe shipping in sturdy containers or crating. Protect all fragile, delicate or sensitive parts with appropriate covers and seals. Protect all elastomer components from exposure to sunlight and inclement weather.

B. Include a packing list of all items in each delivery. Include complete instructions for handling, storing, unpacking, protecting and installing. Submit these documents to Owner's Project

Manager via email to arrive before the equipment is delivered.

C. Contract with a shipper that has the means to safely and effectively deliver the equipment.

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3.02 EXAMINATION & STORAGE

A. Owner will inspect all material and equipment soon after it is received to determine damage and/or missing parts. Supplier will repair or replace damaged items in accordance with the manufacturer's instructions.

3.03 INSTALLATION AND TESTING

A. Each item or system shall be furnished complete. Skilled Owner employees will install the actuators in accordance with the manufacturer's recommendations, instructions, and directions.

B. Owner will install electric actuators above or horizontally adjacent to valve and gear box to optimize access to controls and external handwheel.

3.04 MANUFACTURER'S ON-SITE SERVICES

A. Manufacturer trained technician shall visit plant after the installation of every valve. Plan for one trip per valve to confirm installations has complied with manufacturer instructions.

B. Manufacturer trained technician shall adjust valves, actuators, and appurtenant equipment to comply with intended use. Operate valve, open and close at system pressures.

C. Manufacturer's trained technician shall be available for one call-back visit per valve at Owner request.

D. Refer to the other related sections of this specification for additional installation and testing requirements and information. Tests shall be conducted after all valves are installed.

3.05 OPERATOR TRAINING

A. Provide minimum of one (1) hour of operator training on two separate days for each type of valve and actuator function included in the Project. Schedule training at Owner’s convenience, after system is operational.

END OF SECTION

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APPENDIX A VALVE PEDESTAL DRAWINGS

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APPENDIX B MINNEAPOLIS PUBLIC WORKS SCADA STANDARDS