WRA-3062VALVESPEC.pdf

PUMP SURGE CONTROL VALVE SPECIFICATION

NEWTON STREET

1 – 16” SURGE CONTROL VALVE

Hydraulic controlled, adjustable spring assisted, stop-check stem.

Pump Director Electronic Control Panel.

PART 1 - GENERAL

1.01 SUBMITTALS

A. Submit detailed product data and descriptive literature including dimensions, weights, headloss data, pressure rating, materials of construction, spring calculations, and list of installations in drinking water facilities.

B. Provide shop drawings which clearly illustrate the general arrangement of the equipment and cross-sectional views of the components.

C. Submittals are to be included with the bid to demonstrate compliance with these specifications.

1.02 QUALITY ASSURANCE

A. Supplier shall have been manufacturing electric motor actuated pump control valves with built-in, external spring assisted, mechanical check device for a period of at least five (5) years and shall, at the Engineer's request, provide a list of at least (10) installations involving equipment of similar size and application in drinking water facilities. Contact names and phone numbers shall be provided for list of installations.

PART 2 - PRODUCTS

2.01 SURGE CONTROL VALVES

A. A total of (1) surge control valves shall be furnished. The valve shall be a wye body style.

1. Globe body patterns and/or angle body patterns having a higher headloss in comparison to wye body patterns and/or long-radius elbow body patterns are not acceptable.

B. The Surge Control Valve shall consist of a main valve assembly and electric motor operator, completely assembled, tested and ready for field installation and wiring. The valve size shall be 16 inch diameter. The valve body shall be a one - piece continuous casting.

C. WYE BODY VALVE: The valve body shall be of the in-line, wye pattern, constructed of ductile iron conforming to ASTM A536 with integral flanges faced and drilled to ANSI B16.42 Class

300. The valve shall be inherently self-cleaning and have a inlet flow area through it no less than area of its nominal pipe size. The body shall have a replaceable stainless steel seat. There shall be a clean out/inspection port near the valve seat.

D. The valve disc shall be ductile iron or steel with a renewable seat of ultra-high molecular weight polyethylene, retained by a stainless steel follower ring and stainless steel screws.

E. The valve stem shall be 18-8, non-hardened stainless steel and guided in a long bronze bushing retained in the valve cover. The valve stem shall be sealed where it passes through the body by a pressure actuated seal. A wiper ring shall be used to prevent solids from entering the bearing area.

1. The valve stem shall not be attached to the motor actuator stem so the valve may close upon flow reversal, independent of the motor actuator operation.

2. The valve stem shall be provided with an external, adjustable, spring assist assembly to facilitate the automatic stop-check closure action. Valves with no spring(s) or with internal spring(s) are not acceptable. Spring sizing calculations shall be provided to confirm suitability of spring design for prevailing service conditions.

3. The valve stem shall incorporate a hydraulic oil cylinder arrangement that provides an controlled, adjustable closing speed in the event that the valve closes upon sudden flow reversal that occurs independent of the motor actuator operation. There shall be a lantern ring and vent connection to atmosphere between the oil cylinder seal and valve stem seal in order to prevent hydraulic oil from passing into the main valve body. Hydraulic oil shall be food grade oil in accordance with USDA Class H-1 and/or FDA 21 CFR 178.3620.

The hydraulic circuit speed control shall be disengaged during normal valve operation.

F. The valve shall be equipped with a limit switch mounted on the valve cover to signal when the valve stem has moved to the closed position. Limit switch shall be DPDT, contacts rated

10 amps continuous, with NEMA 4X enclosure. The limit switch shall provide direct indication of the disc position, independent of the electric actuator.

G. The valve shall be equipped with an electric motor actuator with multi-turn, rising stem type gearbox, suitable for open-close, non-throttling pump check service.

1. The motor actuator shall be sized by the valve manufacturer to positively close the wye pattern body style valve against the maximum differential pressure generated at the pump shut-off head of 175 psi with a downstream static system pressure of 90 psi and a static suction head of 34 psi. The minimum time for full stroke (full closed to full open, or full open to full closed) of the valve shall be 180 seconds.

2. The motor actuator shall be rigidly attached to the valve cover with an air gap between the motor actuator and the valve body containing line media.

3. The motor actuator shall be furnished with a 17-4 ph stainless steel rising stem that engages with, but is not mechanically attached to the valve stem.

4. The motor actuator shall be furnished with electric motor and controls housed in a NEMA 4 housing, in accordance with AWWA C540. Controls shall include limit switches, 8 wire torque switches, reversing starter(s), control transformer, local-off-remote selector switch, local open-close pushbuttons, status lights, manual handwheel with hand-auto lever, and visual position indicator. Motor actuator controls shall be suitable for operation with 460 volt 60 hz 3 phase power source. Limit switches and relay(s) shall be provided by the valve manufacturer to properly function with the local and SCADA controls.

5. Motor actuator controls shall include a stepping timer module that allows the valve stroking time to be increased for the entire or any portion of the valve travel. The start and stop point of the stepping mode shall be manually adjustable for any portion of the valve stroke. The on- and off-time intervals within the stepping mode shall be manually adjustable between 1 and 30 seconds.

6. Motor actuator controls shall include a valve position output signal of [4-20 mA] [variable resistance], separate from the valve position feedback signal described above.

2.02 PUMP DIRECTOR ELECTRONIC CONTROL PANEL

A. The Pump Director shall function as a pump starter controller and Surge Control Valve sequencer. The control box shall provide appropriate light indications of the pump and pump control valve operational status. The valve manufacturer shall provide all components to properly function with the existing local and SCADA controls.

B. The Pump Director shall be housed in a NEMA 4 rated steel enclosure with gasketed door, “Oil tight” lights, with baked enamel finish. The enclosure dimensions shall be no larger than 12” x 14” x 6” and shall be provided with (4) mounting holes for wall or panel mounting.

The following light indications shall be provided:

1. Amber shall indicate 120 volt 60 hz power supply is applied to Pump Director; failure of power supply – emergency mode #1.

2. Flashing blue shall indicate a pump start command and initiation of VDT timing sequence.

3. Steady blue shall indicate that pump discharge exceeds static system head (pressure switch setting).

4. Flashing green shall indicate valve open command and initiation of VIT timing sequence.

5. Steady green shall indicate normal pump and check valve operation.

6. Yellow (neon) shall indicate power failure delay timer activated; emergency mode #2.

7. Flashing red shall indicate failure of pump to develop pressure on start-up and VDT timer expired; emergency mode #3.

8. Flashing red shall indicate failure of valve to open on start-up and VIT timer expired;

emergency mode #4.

9. Flashing red shall indicate premature valve closure; emergency mode #5.

10. Flashing red shall indicate loss of pump pressure during normal pump operation; emergency mode #6.

11. All of the indicator lights shall be oil-tight and shall be provided with “push to test” operation.

C. In addition to the visual light indications, individual contacts shall be provided for remote indication of emergency modes #1 through #6. Emergency contacts shall be dry, normally open type rated for 1.5 amp 120 VAC and shall provide continuous contact closure for each of the emergency modes.

D. A three position, “Hand-Off-Automatic” (HOA) switch shall be provided to allow local or remote pump start/pump stop operation. The “Off” position shall also function as a reset for emergency modes #2 through #6.

E. Solid state, adjustable timers shall be provided for VDT and VIT delay sequences. Adjustable range shall be no less than 100 seconds. Solid state timer pre-set for five minute delay shall be provided for power failure delay sequence.

F. Terminal strips shall be provided for all required connections to valve controls, pump motor starter, anti-plugging switch, remote pump start/stop, pressure switch and remote emergency mode indication.

G. In addition to the Pump Director, a pressure switch shall be provided to be mounted between the pump discharge and check valve inlet. The pressure switch shall be SPDT type with adjustable setpoint, suitable for system pressure conditions.

H. Normal Pump Start (Hand or Auto)

1. A command to start the pump, by either turning the HOA switch to “Hand” position or remote contact closure with HOA switch in “Auto” position, will cause contact closure to the pump motor starter circuit. Contacts to motor starter shall be dry, normally open type rated for 20 amp 120 VAC.

a. The pump starts and a flashing blue light shall be displayed. The VDT (Valve Delay Timer) delay sequence shall be initiated simultaneously with the pump start. The flashing blue light shall be displayed until pump discharge pressure exceeds the pressure as set on pump discharge pressure switch, or until the VDT delay timer expires.

b. Failure of the pump to produce sufficient pressure to satisfy the pressure switch setting within the VDT timer setting shall cause a flashing red light to be displayed indicating “Insufficient pump pressure on start-up”, emergency mode #3. Motor starter contacts shall open, de-energizing pump motor, if emergency mode #3 activated. A manual “reset” of the HOA switch shall be required to restart the pump.

2. When pump discharge pressure exceeds the pressure switch setting prior to expiration of VDT timer setting, the flashing blue light shall become steady blue and the steady blue light shall be displayed for the duration of the VDT timer setting.

3. Upon expiration of the VDT timer setting, the Surge Control Valve’s electric motor actuator shall be directed to open and a flashing green light shall be displayed. The VIT (Valve Initiate Timer) delay sequence shall be initiated.

a. The flashing green light shall be displayed until the valve opens and actuates the limit switch or until the VIT timer expires.

b. Failure of the Surge Control Valve to open within the VIT timer setting shall cause a flashing red light to be displayed indicating “Valve Did Not Open on Start-Up”;

emergency mode #4. Pump motor starter contacts shall open, de-energizing pump motor and the electric motor actuator shall de-energize. A manual “reset” of the HOA switch shall be required to restart the pump.

4. When the Surge Control Valve opens and trips the limit switch prior to expiration of VIT timer setting, the flashing green light shall become steady green. The steady green light shall be displayed for the duration of the pumping operation.

I. Normal Pump Shutdown (Hand or Auto)

1. A normal pump shutdown sequence shall be initiated by either turning the HOA switch to the “Off” position, or by opening the circuit across the “external control” contacts with the HOA switch in the “Auto” position. The Surge Control Valve’s electric motor actuator shall be directed to close.

2. At approximately 95% closed, the valve shall actuate a limit switch that shall open the motor starter contacts and de-energize the pump motor. The Surge Control Valve shall continue to the fully closed position. When the electric check valve is closed and the pump de-energized, the steady green light shall be extinguished.

J. Valve Malfunction - If for any reason the Surge Control Valve closes without a normal pump shutdown command, the motor starter contacts shall open thereby de-energizing the pump motor. A flashing red light shall be displayed indicating “Valve Malfunction – Closed Without Command”; emergency mode #5. A manual “reset” of the HOA switch shall be required to restart the pump.

K. Pump Malfunction - If during the pumping operation the pump discharge pressure was not able to satisfy the pressure switch setting the pump motor starter contacts will open thereby de-energizing the pump motor. The Surge Control Valve’s electric motor actuator shall be directed to close and the integral check feature will close immediately upon pressure reversal to prevent backflow. A flashing red light shall be displayed indicating “Loss of Pump Pressure to Pressure Switch”;

emergency mode #6. A manual “reset” of the HOA switch shall be required to restart the pump.

L. Power Failure - In the event of a power failure, even momentary, the pump motor will be disengaged and the Surge Control Valve’s integral check feature will close immediately upon pressure reversal to prevent backflow.

1. The Surge Control Valve shall be directed to close as soon as power is restored and a five-minute time delay period shall be initiated. During the power failure delay period, it shall not be possible to have an automatic pump restart. A yellow (neon) light shall be displayed during the delay period.

2. After the delay period has expired and the Surge Control Valve’s electric motor actuator is in the fully closed position, a normal pump start sequence shall be initiated (if a local or remote pump start command exists). It shall be possible to cancel the delay period by a manual reset of the HOA switch. It shall be possible to change the delay period from 6 seconds to 10 minutes; or to infinity in order to prevent a pump restart without a reset of the HOA switch.

M. Anti-Plugging Switch - Contacts shall be provided for anti-plugging switch from the pump in order to prevent a pump start during reversing of the pump.

2.03 FUNCTION

A. The valve shall function to control surges associated with the starting and stopping of pumps.

B. The total head loss across the valve shall be no greater than 6 feet when passing a flow rate of

14,000 GPM.

C. The valve shall open slowly upon receipt of open signal (maintained contact closure to the Pump Director remote control terminals or local "Hand Run" command from Pump Director) after the pump has been started and has come up to pressure.

D. The valve shall close slowly upon receipt of close signal (open contacts to the Pump Director remote control terminals or local "Off" command from Pump Director) against the running pump.

After the valve has fully closed, a valve-closed limit switch shall turn off the pump.

E. Anytime the valve is open and valve outlet pressure exceeds valve inlet pressure, the valve shall close quickly and independently of the motor actuator to prevent excess backflow through the pump. If sudden backflow should occur, independent of motor actuator operation, the valve stem closure speed shall be adjustable by means of the hydraulic oil cylinder assembly.

2.04 MANUFACTURER

A. The valve shall be the Series 1600-M Universal Pump Control Valve (Checktronic Valve) as manufactured by GA Industries, Inc., Cranberry Township, PA.

B. or equal

3.02 Manufacturer's Field Service

A. Manufacturer's authorized representative shall be present at the jobsite for assistance during equipment start-up and to train owner's personnel in the operation, maintenance and troubleshooting of the equipment provided.