PWS_2024_Blue_Marsh_Bernville_Sluice_Gate_Actuators.pdf

Performance Work Statement

Sluice Gate Actuators US Army Corps of Engineers

Blue Marsh Lake

1.0 Introduction

1.1 Background. Blue Marsh Lake is located at 1268 Palisades Dr, Leesport PA, 19533. The dam was constructed to reduce flood risks primarily for the Schuylkill River Valley. In addition, Blue Marsh is Congressionally authorized for recreation and water supply. The reservoir is part of the Delaware River Basin Flood Control program and is operated and maintained by the US Army Corps of Engineers, Philadelphia District. The Blue Marsh Lake project also includes the Bernville Protective Works which consists of a pumping station, levee, ponding area, gravity outlets, and detention dams.

One of the many components of the Bernville Pumping Station is six (6) storm water sluice gates.

Each gate is 84”x84”, manufactured by Waterman Industries Inc, model no QS-55-20-F-AS. The existing watertight electrical gate actuators and gear boxes that operate these gates are manufactured by Rotork Inc., model 40A Syncropak II.

The storm water sluice gates remain closed until the ponding level reaches a certain elevation and trips the gate opening float switch for each gate. At this point, the electric actuator and gear box independently wired to an individual gate will automatically open said gate. This allows water to enter the pumping station from the interior drainage area, and one of six (6) storm water pumps propels the water into the Northkill Creek.

The electrical gate operators and gear boxes that activate these gates are integral to the flood risk management mission. Since this is an unattended station, all equipment must be maintained and operated in a constant state of readiness. Recently, two (2) of the six (6) electric gate operators experienced component failure. USACE reached out directly to Rotork Inc. and inquired about rehabbing existing equipment. It was determined the Rotork Inc. model 40A Syncropak II is obsolete and no longer available. The units were manufactured over 40 years ago and replacement parts would need to be special ordered and manufactured. It was determined the most cost-effective approach is to install a modern Rotork equivalent IQ3 actuator. An IQ3 Rotork actuator is required for compatibility purposes to retrofit existing gate operating equipment and ensure a functional system.

1.2 Scope of Work. This is a supply contract procuring four (4) Rotork IQ-35 Electric Actuators and four (4) Rotork IB-7 Gearboxes. The Contractor shall furnish these items per the specifications of the salient characteristics and features listed in Section 3.0 under Performance Requirements.

2.0 General Requirements

A required supply contract shall be provided at Blue Marsh Lake as described in the following sections.

2.1 General. The Contractor agrees to furnish equipment as described in Section 3 under Performance Requirements. The Contractor shall deliver to the project site no longer than 180 days after award.

2.2 Government-Furnished Materials. The Contractor is expected to provide all manpower, equipment, supplies, and materials required to deliver the actuators and gearboxes to 1268 Palisades Dr, Leesport PA, 19533.

2.3 Contractor Personnel, Disciplines, and Specialties. The Contractor must be registered in System for Award Management, (www.sam.gov) have a DUNS# and Cage Code to provide. The Contractor must use GSA and other Governmental pricing schedules where applicable.

2.4 Location and Hours of Duty. The Contractor shall deliver only during normal Corps of Engineers duty hours (7:00 am. to 3:30 pm., Monday thru Friday, excluding Federal holidays) weather permitting.

3.0 Performance Requirements.

The Contractor shall provide four (4) Rotork IQ-35 Electric Actuators with IB-7 Gearboxes per specifications of the salient characteristics listed below. They should include but are not limited to the following features:

3.1 General. The actuators shall be suitable for use on a nominal _208 volt, _3 phase, _60 Hz power supply and are to incorporate motor, integral reversing starter, local control facilities and terminals for remote control and indication connections housed within a self-contained, sealed enclosure.

As a minimum, the actuators should meet the requirements set out in EN15714-2 and ISA SP96.02 In order to maintain the integrity of the enclosure, setting of the torque levels, position limits and configuration of the indication contacts must be carried out without the removal of any actuator covers and without mains power over an Infrared or Bluetooth® wireless interface. Sufficient commissioning tools must be provided with the actuators and must meet the enclosure protection and certification levels of the actuators. Commissioning tools must not form an integral part of the actuator and must be removable for secure storage / authorized release. In addition, provision shall be made for the protection of configured actuator settings by a means independent of access to the commissioning tool. Provision shall be made to disable Bluetooth® communications or only allow a Bluetooth® connection initiated by an Infra-Red command for maximum security. The actuator shall include a device to ensure that the motor runs with the correct rotation for the required direction of valve travel irrespective of the connection sequence of the power supply.

3.2 Actuator Sizing. The actuator must be sized to guarantee valve closure at the specified differential pressure and temperature. The safety margin of motor power available for seating and unseating the valve must be sufficient to ensure torque switch trip at maximum valve torque with the supply voltage 10% below nominal. For linear operating valves, the operating speed shall be such as to give valve closing and opening at approximately 10-12 inches per minute.

3.3 Environmental. Actuators must be suitable for indoor and outdoor use with a standard corrosivity category, C4 medium durability as per ISO 12944. The actuator must be capable of functioning in an ambient temperature ranging from -30°C (-22°F) to +70°C (+158°F), up to 100% relative humidity.

http://www.sam.gov/

3.4 Enclosure. Actuators shall be O-ring sealed, watertight to IP66/IP68 20m for 10 days, NEMA 4,

6. The motor and all other internal electrical elements of the actuator must be protected from ingress of moisture and dust when the terminal cover is removed for site cabling. The terminal compartment must maintain the same ingress protection rating with the terminal cover removed.

The actuator enclosure must allow for temporary site storage without the need for electrical supply connection. All external fasteners shall be suitable for the actuator corrosivity category and installation environment indicated on the datasheet.

3.5 Motor. The motor must be an integral part of the actuator, designed specifically for valve actuator applications. The motor shall be a low inertia, high torque design and class F insulated. Resulting in class B temperature rise with a time rating of 15 minutes at 40°C (104°F) at an average load of at least 33% of maximum valve torque. Temperature shall be limited by thermostat device embedded in the motor end windings and integrated into the actuator control. Electrical and mechanical disconnection of the motor shall be possible without draining the lubricant from the actuator gearcase. The actuator shall include a device to ensure that the motor runs with the correct rotation for the required direction of valve travel irrespective of the connection sequence of the power supply.

3.6 Motor Protection. Protection must be provided for the motor in the following phases.

3.6.1 Stall – The motor must be de-energized within 8 seconds in the event of a stall when attempting to unseat a jammed valve.

3.6.2 Over temperature – thermostat will cause tripping of the motor. Auto-reset on cooling.

3.6.3 Single Phasing – lost phase protection

3.6.4 Direction – phase rotation correction

3.7 Gearing. The actuator gearing must be totally enclosed in an oil-filled gearcase suitable for operation at any angle. Grease lubrication is not permissible. All drive gearing and components must be of metal construction and incorporate a lost-motion hammer blow feature. For rising spindle valves the output shaft shall be hollow to accept a rising stem and incorporate thrust bearings of the ball or roller type at the base of the actuator. The design should be such as to permit the opening of the gearcase for inspection or disassembled without releasing the stem thrust or taking the valve out of service.

3.8 Hand Operation. A handwheel must be provided for emergency operation, engaged when the motor is declutched by a lever or similar means, the drive being restored to electrical operation automatically by starting the motor. The handwheel or selection lever must not move on restoration of motor drive. Provision shall be made for the hand/auto selection lever to be locked in both hand and auto positions. It should be possible to select hand operation while the actuator is running or start the actuator motor while the hand/auto selection lever is locked in hand without damage to the drive train. Clockwise operation of the handwheel must give closing movement of the valve.

3.9 Drive Interface. The actuator shall be furnished with a drive bushing easily detachable for machining to suit the valve stem or gearbox input shaft. The drive bush shall be positioned in the base of the actuator. Thrust bearings shall be sealed for life and the base shall be capable of withstanding five times the rated thrust of the actuator.

3.10 Local Controls. The actuator must incorporate local controls for Open, Close and Stop operation and a Local/Stop/Remote mode selector switch. Mode selection must be lockable in any one of the following three positions: local control plus local stop only, stop (no electrical operation), remote control plus local stop only. It must be possible to select maintained or non-maintained local control.

3.11 Torque and Limits. Torque and turns limitation to be adjustable as follows:

Position setting range – multi-turn: 2.5 to 8,000 turns, with resolution to 7.5° of actuator output.

Position setting range – direct drive part turn actuators: 90° +/-10°, with resolution to 0.1° of actuator output.

Torque setting - 40% to 100% rated torque.

3.12 Position measurement. Absolute position measurement should be incorporated within the actuator. The technology must be capable of reliably measuring position even in the case of a single fault. The design must be simple with the minimum amount of moving parts (no more than 5). Technologies such as LEDs or potentiometers for position measurement are considered unreliable and therefore not preferred. Measurement of torque for multi-turn actuators must be from direct measurement of force at the output of the actuator. Methods of determining torque-using data derived from the motor such as motor speed, current, flux are only acceptable for part-turn actuators. A means for automatic “torque switch bypass” to inhibit torque off during valve unseating and “latching” to prevent torque switch hammer under maintained or repeated control signals shall be provided. The electrical circuit diagram of the actuator should not vary with valve type remaining identical regardless of whether the valve is to open or close on torque or position limit.

3.13 Local Position Indication. The local controls shall be arranged so that the direction of valve travel can be reversed without the necessity of stopping the actuator. The actuator display must include a dedicated numeric/symbol digital position indicator displaying valve position from fully open to fully close in 0.1% increments. Valve closed and open positions shall be indicated by symbols showing valve position in relation to the pipework to ensure that valve status is clearly interpreted. With mains power connected, the display must be backlit to enhance contrast at all ambient light levels and must be legible from a distance of at least 5m (16ft). A power save mode shall be available to switch off the display backlight during long periods of inactivity.

Red, green, and yellow LEDs corresponding to open, closed and intermediate valve positions must be included on the actuator display when power is switched on. The yellow LED should also be fully programmable for on/off, blinker and fault indication. The digital display must be maintained and updated during handwheel operation when mains power to the actuator is isolated.

The actuator display shall include a fully configurable dot-matrix display element with a minimum pixel resolution of 168 x 132 to display operational, alarm, configuration and graphical datalogger information. The text display shall be selectable between English and other languages such as:

Spanish, German, French, and Italian. Provision shall be made to upload a different language without removal of any covers or using specialized tools not provided as standard with the actuator.

Datalogger graphical displays and trend graphs must be available on the local LCD for the following functions:

• Torque versus Position

• Number of Starts versus Position

• Number of starts per hour

• Dwell Time

• Average temperature

The main display must include configurable a minimum of four different home-screens that include the following information:

• Position and status

• Position and torque (analogue)

• Position and torque (digital)

• Position and demand (positioning)

An optional environmental cover to protect the display from high levels of UV radiation or abrasive materials must be available and shall be fitted without the need for any special tooling.

The local controls and display must be rotatable through increments of 90 degrees to suit valve and actuator installation orientation.

3.14 Integral Starter and Transformer. The reversing starter, control transformer and local controls must be integral to the valve actuator and suitably housed to prevent breathing and condensation.

The starter shall be suitable for 60 starts per hour during normal service or 1,200 starts per hour under reduced load conditions and of rating appropriate to motor size. The controls supply transformer shall be fed from two of the incoming three phases and incorporate overload protection. It must have the necessary voltage tapping and be adequately rated to provide power for the following functions:

• Energizing of the contactor coils

• 24V DC or 110V AC output for remote controls (maximum 5W/VA)

• Supply for all the internal electrical circuits

An alternative solid state motor starter is permissible for applications requiring up to 1,200 starts per hour. 24VDC remote controls should be used in combination with a solid-state starter to maximize response time. The solid-state starter must facilitate configurable electrical braking functionality. Speed adjustable actuators must have an integral motor controller to manage starting, speed and operation.

3.15 Remote Control Facilities. The necessary control, wiring and terminals must be contained within the actuator enclosure. Open and close external interlocks must be made available to inhibit local and remote valve opening / closing control. It must be possible to configure the interlocks to be active in remote control only. Remote control signals fed from an internal 24VDC (or 110VAC) supply and/or from an external supply between 20V and 60VDC or 40V and 120VAC, must be suitable for any one or more of the following methods of control:

• Open, Close and Stop control

• Open and Close maintained or “push to run” (inching) control

• Overriding Emergency Shut-Down; to close (or open) valve from a normally closed or open contact

• Two-wire control; energize to close (or open), de-energize to open (or close)

Additionally, provision shall be made for a separate ‘drive enable’ permissive input to prevent any unwanted electrical operation. It must be possible to reverse valve travel without the necessity of stopping the actuator or moving through an intermediate stop control position. The motor starter must be protected from excessive current surges during rapid travel reversal. The internal circuits associated with the remote control and monitoring functions are to be designed to withstand simulated lightning impulses up to 2kV.

Operation by distributed control system must be possible utilizing one or more of the following network systems:

• Profibus

• Modbus

• Foundation Fieldbus

• DeviceNet

• Pakscan

• HART

3.16 Monitoring Facilities. Facilities to indicate actuator availability and monitor operation must be included as standard.

• Actuator text display indication of the following status/alarms:

• Closed Limit, open limit, moving open, moving closed, stopped

• Torque trip closing, torque trip opening, motor stalled

• ESD active, interlock active

• Thermostat trip, phase lost, 24V supply lost, local control failure

• Configuration error, position sensor failure, torque sensor failure

• Battery low, battery discharged, power loss inhibit

Integral datalogger to record and store the following operational data:

• Opening last / average torque against position

• Closing last / average torque against position

• Opening motor starts against position

• Closing motor starts against position

• Total open / closed operations

• Maximum recorded opening and closing torque values

• Event recorder logging operational conditions (valve, control and actuator)

The event log must include time and date information for each stored event. Logged data must be accessible via non-intrusive Bluetooth® communication and also visible on the actuator display.

An intrinsically safe portable tool must be provided to extract datalogger and actuator configuration files from the actuator. The portable tool must permit Bluetooth® connection with a PC to perform file transfer. The actuator manufacturer must supply PC software to enable extracted actuator files to be viewed and analyzed.

3.17 Wiring and Termination. Internal wiring shall be tropical grade PVC insulated stranded cable of appropriate size for the control and power. Each wire shall be clearly identified at both ends.

The terminals shall be embedded in a terminal block of high tracking resistance compound. The terminal compartment must be separated from the inner electrical components of the actuator by means of a watertight seal. A minimum of four threaded cable entries with provision for an additional four extra conduit entries must be available to accommodate wiring connections. All wiring supplied as part of the actuator must be contained within the main enclosure for physical and environmental protection. External conduit connections between components are not acceptable. A durable terminal identification card showing a plan of terminals must be attached to the inside of the terminal box cover indicating:

• Serial number

• External voltage values

• Wiring diagram number

• Terminal layout

The code card must be suitable for the contractor to inscribe cable core identification alongside terminal numbers. Each actuator must be supplied with a start-up kit comprising installation instruction manual, with the electrical wiring diagram attached as Appendix B, and cover seals to make good any site losses during the commissioning period. In addition, sufficient actuator commissioning tools shall be supplied to enable actuator set up and adjustment during valve/actuator testing and site installation commissioning. Additionally, each actuator must be furnished with a test certificate from Rotork.

4.0 Measure and Payment

Payment will be made after delivery and upon satisfied completion by the Authorized Representative of the Contracting Officer (COR), Joshua Dinko. Compensation is for all manpower, equipment, supplies, and materials required to deliver the actuators to US Army Corps of Engineers, Blue Marsh Lake. Upon satisfaction of the contract, the Contractor shall submit an invoice(s) for payment to:

Joshua E. Dinko Facility Operations Specialist

2145 Pohopoco Drive Lehighton, PA 18235

Joshua.E.Dinko@usace.army.mil 610-377-0332

The invoice should be submitted within five (5) calendar days after delivery. The invoices must provide, Contractor’s name and address, Contract/Purchase Order No., date prepared and itemized costing per unit.

Questions regarding the preparation and forwarding of invoices may be directed to the COR.

mailto:Nathan.T.Freiwald@usace.army.mil

A

H

G

F

E

D

C

B

1 12111098765432

Drawing Number Sheet NoIssue NoA2

Scale: THIRD ANGLE PROJECTION

Title

Drawn

Ref Project Ref www.rotork.com

Checked

Bath, BA1 3JQ, England.

Telephone 01225-733200

Rotork Controls Limited Date

1:5

Actuator Size:

Issue Description

3 Gearbox ratios changed

TCE

QUOTATION

13-MAR-15

3SALES II3SHWIB7STD

NJC

:DIMENSIONS WITH '*' INDICATE

VALVE SHOULD CONFORM TO GOOD ENGINEERING

PRACTICES, ENSURING ADEQUATELY TOLERANCED

LIMITS FOR PARALLELISM, PERPENDICULARITY

AND CONCENTRICITY.

ACTUATOR OR SECOND STAGE GEARBOX ONTO THE

OUR EQUIPMENT CAUSED BY EXCESSIVE LOADING

:ROTORK CANNOT BE HELD LIABLE FOR DAMAGE TO

:THE INTERFACE PROVIDED FOR MOUNTING THE

:NETT WEIGHT =

COVER REMOVAL ALLOWANCE

: = OIL FILLER/DRAIN PLUG

NOTES:

FROM COVER TUBES. (SEE ALSO PUB000-124)

F16:110kg/242lbs,F25:120kg/264lbs

:ELECTRONICS COVER OPTION "**" WILL

VARY DEPENDING ON CONFIGURATION

Plugged

CONDUIT ENTRIES

Hole 3Hole 2 Size

Gland

Hole 1 Hole 4 As Required

As Required

As Required

As Required

As Required

As Required

As Required

As Required

As Required

As Required

As Required

As Required

5.00"

Maximum Bore & Key

Key form O Bore

Rectangle (BS4235)

Key size

No. Holes

PCD

Hole size

Designation

Gearbox output flange options

Rectangle (ANSI B17.1)

Square (ANSI B17.1)

-4

M20

F16

3/4" UNC

6.5"

FA16

68 20 X 12

2-5/8" 5/8 X 7/16"

2-1/2" 5/8"

M16

F25

5/8" UNC

10"

FA25IQ35, SIDE HANDWHEEL, IB7

F14/FA14/F16/FA16 Ratios 3:1, 4:1 & 6:1 Installation Details

IQ35, IB7, F16/F25/FA16/FA25

ISOMETRIC VIEW

(SCALE 1:12)

MOTOR

M6 EARTH STUD

FITTED AS

REQUIRED

ELECTRONICS COVER (LONG) **

TERMINAL HOUSING

BATTERY HOUSING

.8

LOCAL/REMOTE/STOP

SWITCH

OPEN/CLOSE SWITCH

DISPLAY WINDOW

CONDUIT ADAPTERS

AS REQUIRED

(MAX HEIGHT 40.00mm)

.5 ø

ELECTRONICS COVER (SHORT) **

q

HANDWHEEL O210

SEE GEARBOX OUTPUT

FLANGE OPTIONS TABLE

.2

IDENTIFICATION PLATE

6.88" *

9.06" *

15.44"

3.30"

8.86" *

15.02"

17.42"

.9

.7

.0

O

.0

O

.3

.6

.3 q

6.81"

TO SUIT

VALVE TRAVEL

.8

.2

O

0.19"

3.39"

SEE MAXIMUM BORE & KEY TABLE

2108.27"

O

.1

11.99"

8.46"

45°

O129.90/129.95 (F16)

4.995"/4.985" (FA16)

199.95/199.90 (F25)

5.998"/6.000" (FA25)

4.73"

6.27"

6.70"

PADLOCKABLE HAND-AUTO LEVER

LEVER POSITION IN AUTO.

LEVER AUTOMATICALLY RETURNS

TO THIS POSITION WHEN RELEASED.

Scale 1:6

1405.52"

30°

50°

TO ENGAGE

HAND

USE O6.5

(1/4" Dia)

PADLOCK.

PADLOCKABLE HAND-AUTO LEVER

LEVER POSITION IN AUTO.

LEVER AUTOMATICALLY RETURNS

TO THIS POSITION WHEN RELEASED.

Scale 1:6

1405.52"

30°

50°

TO ENGAGE

HAND

USE O6.5

(1/4" Dia)

PADLOCK.

PADLOCKABLE HAND-AUTO LEVER

LEVER POSITION IN AUTO.

LEVER AUTOMATICALLY RETURNS

TO THIS POSITION WHEN RELEASED.

Scale 1:6

1405.52"

30°

50°

TO ENGAGE

HAND

USE O6.5

(1/4" Dia)

PADLOCK.

Appendix A

IQ3

CIRCUIT DRAWN WITH POWER SUPPLY OFF

Iss Date Revision DetailsChkd

SheetROTORK CONTROLS LTD ROTORK CONTROLS INC

BATH, BA1 3JQ ROCHESTER

Tel:01225-733200 Tel:585-247-2304

ENGLAND NY 14624, USA

Issue No

Circuit Diagram Number

MI No :

Date :

Base WD:

Drawn by:

Job No :

FOR TYPICAL REMOTE CONTROL

DETAILS, SEE DOCUMENT

of 2 www. .comwww. .com

1110B0000

PMJ

160512

IQ + 120VAC REMOTE CONTROL SUPPLY.

7110B0000 B1 C1B2 C2

RWS101

IQ3

TORQUE

SENSOR

SK2

E

POSITION

SENSOR

BATTERY

FS2 (IF FITTED) 100mA

CLOSE

STOP/ MAINTAIN

COMMON -VE

ESD

OPEN INTERLOCK

CLOSE INTERLOCK

S1MAKE AT FULLY SHUT

S2MAKE AT FULLY OPEN

S3BREAK AT FULLY SHUT

S4BREAK AT FULLY OPEN

MONITOR RELAY

C1 C2

V

W

M

SK13

SK13

OPEN

COMMON -VE

SK14

SK7

0VAC

120VAC

0VDC

24VDC

SK3

SK8

SK9

10 WAY

26 WAY

18 WAY

SK650%

SLOT B

SK2

SK4

U W X Y Z

V

FS1

SK14

0VDC

24VDC 2

PS1

TRANSISTOR SWITCHING FOR

24VDC CONTACTORS (IQ10-35)

RELAYS ONLY FITTED WHEN

120VAC CONTACTOR IS FITTED

FOR IQ40,70,90,91 & 95

CLOSED

SLOT A

SK1

U W

REFER TO SHEET 2 FOR NOTES

& OPTION PCB'S IF FITTED

120VAC

NOMINAL SUPPLY

(OUTPUT)

PHASE

SUPPLY

U

OPEN

STOP

REMOTE

LOCAL

Tap Nominal 50/60Hz

W 220/230

X 380/400

Y 400,415/420

Z 440/460

W 346/380

X 480/500

Y 240/240

Z 550/575

X 660/660-690

Y 690/-

F US E F S 1= 250mA A NTI-S UR G E

F US E F S 1= 250mA A NTI-S UR G E

F US E F S 1= 150mA A NTI-S UR G E

TR ANS F OR ME R TAP P ING OP TIONS

TYP E 1

TYP E 2

TYP E 3

090113 PMJ Re-track of the 24V DC pin on SK14 to behind the diode.

6 170413 JHW RWS WAS 100

180614 MR7 400v added to type 1 tapping Y. Note added to sheet 2 note 1.

Appendix B