GENERAL This document describes the minimum requirements for the design, manufacture, testing and supply and installation of valves, appurtenances complete with frames, supports, anchor bolts, stems, stem guides and other appurtenances. It shall be the Contractor responsibility to be, or to become, knowledgeable of the requirements of the referenced Codes and Standards and to ensure that all equipment, systems, installations, packages are designed, manufactured and tested accordingly. The Codes, Standards, Specifications including its referenced documents and statutory regulations referred in this document, form a part of this Specification. Unless specified otherwise, the latest edition in force at the time of award of Contract shall apply. In case of conflict between the standards, the more stringent requirement shall govern.
SUBMITTALS The Contractor shall submit to the Client, the following items for review and approval before commencing Work: A. Valves:
• Certificate of compliance stating that the Valves and all materials used in its construction conform to all requirements according to the Specification.
• Certificate of testing including test data to show that all tests specified have been performed and all requirements have been met.
• Manufacturer’s recommended specification and instructions for transporting, handling, loading, unloading and storage of Valves.
• Catalog data showing illustrations and schedule of parts and the material of which they are made to facilitate assembly and disassembly and ordering of replacement parts, as well as the net assembled weight of the valves.
• Maintenance manual showing periodic maintenance including lubrication requirements and procedure, and recommended spare parts list.
• Drawings showing the principal dimensions, construction details, and materials.
• The following information shall be submitted by the valve manufacturer:
a. Valve port diameter.
b. Clearances required for the actuator and clearances require to remove the actuator.
c. The number of turns to open and close for actuators.
d. Assembled weight.
e. Valve-torque data. f. Cavitation coefficients.
g. Valve component materials
h. Principal dimensions, including laying length
i. Actuator manufacturer, model, and torque capability for automated valves
j. Interior and exterior coating materials
k. Clearance B. Actuators: The manufacturer shall submit the following:
• Storage- installation- and operation instruction as well as electric wiring diagram, dimensional drawings and technical data sheet including motor data as per manufacturer standard.
• Specifications of the enclosure and the components of the equipment with relevant sheets of manufacturer’s catalogues.
• The torque-speed requirement calculations.
1. DATA SHEET FOR BALL VALVE Vendor's Description Specification Confirmation General Data Manufacture r To be filled by Vendor/Contractor Model Number To be filled by Vendor/Contractor Valve Tag To be filled by Vendor/Contractor as per the P&ID drawing Valve Type Ball Valve Fluid Treated Sewage Effluent Size(s), NB Φ800 Connecting Pipe material Carbon Steel Pressure Rating (Bar) 10 and 25 Design Design/Man ufacturing Standard EN 1074 - 2 Face to Face Dimension standard EN 558 Flange Drilling Standard EN 1092-2 Type of connection Flanged, RF Function Isolation Valve Mode Electrical actuator with manual override Gearbox with of Operation handwheel, square stem cap, Flow Direction Bi-Directional Material of Construction Body ASTM A 216 Gr. WCB ASTM A 105, or special cast (at least equivalent to ASTM A 395 / A 395M); stainless steel welded overlay with 3 Ball Plug mm minimum thickness. Seat austenitic Cr-Ni steel Seal PTFE or equivalent Shaft ASTM A 182 Gr. F316L or Gr. F316LN Internal & Inside & Outside Fusion bonded pure epoxy resin with dry External film, 300µm thick Coating Codes & Standards /Testing/ Certification Pressure test & Leakage test API 6D/ ISO 14313 Leakage Class EN 12266, A Material certification BS EN 10204 TYP. 3.1 Marking API 6D/ ISO 14313
Notes:
1. Valves shall have a clear waterway equal to the full nominal diameter of the valve and shall be opened by turning counter-clockwise.
2. The operating nut or wheel shall have an arrow, cast in the metal, indicating the direction of opening.
3. The vendor shall confirm the compatibility of the material with respect to the fluid service. 2. DATA SHEET FOR BUTTERFLY VALVE Φ900, Φ1600 Description Specification Vendor's Confirmation General Data To be filled by Manufacturer Vendor/Contractor To be filled by Model Number Vendor/Contractor To be filled by Valve Tag Vendor/Contractor as per the P&ID drawing Dry, Indoor, at TSE main Installation pump suction and lift station Butterfly valve Valve Type - Resilient Seat, Short Pattern Fluid Treated Sewage Effluent Size(s) Φ 900 , Φ1600 Connecting Pipe material Carbon Steel Pressure Rating (Bar) 10 Design Design/Manufacturing Standard BS EN 593 / AWWA C504 Face to Face Dimension standard EN 558 Flange Drilling Standard EN 1092-2 Type of connection Flanged, RF Type of Disc Design Double Eccentric Function/Operation Isolation (On/Off) Electrical actuator with manual override Gearbox Valve Mode of Operation with handwheel, square stem cap, Resilient seated Seat Design (Replaceable) Flow Direction Bi-Directional Material of Construction Body Ductile Iron ASTM A536 Disc Ductile Iron ASTM A536 Duplex Stainless steel Shaft (1.4462) Shaft bearing Bronze / PTFE composite Seal Ring PTFE or equivalent O Ring EPDM, ASTM D2000 Fasteners Stainless Steel, Gr 316L Extension Spindle Stainless Steel, Gr 316L Inside & Outside Fusion Coating (Body) Internal/External bonded pure epoxy resin with dry film, 300µm thick
Coating (Disc) EPDM, ASTM D2000
Detailed material takeoff from To be filled by manufacturer attached (Yes/No) Vendor/Contractor Handwheel Ductile Iron ASTM A536 Codes & Standards /Testing/ Certification Pressure test & Leakage test API 6D/ ISO 14313 Leakage Class EN 12266, A Material certification BS EN 10204 TYP. 3.1 Marking API 6D/ ISO 14313
Note: 1.The butterfly valves shall be equipped with disc drive actuators meeting AWWA C504 design equivalent BS EN standards requirements. Disc drive actuators shall be self- locking, high mechanical advantage to ensure low input efforts to reduce water hammer and could be directly mounted on top of the butterfly valve. 2. The butterfly valves shall be rated for zero-leakage (drip-tight) closure. Valve seats shall be designed to be leak-tight in both directions at differential pressures up to, and including, the rated pressure of the valve class. 3. The vendor shall confirm the compatibility of the material with respect to the fluid service. 4. All valves that are operated by actuators are controlled by SCADA. 3. DATA SHEET FOR BUTTER FLY VALVE, Φ1500, Φ1800 Description Specification Vendor's Confirmation General Data Manufacturer To be filled by Vendor/Contractor Model Number To be filled by Vendor/Contractor To be filled by Vendor/Contractor as per Valve Tag the P&ID drawing. Instillation Outdoor Butterfly valve Valve Type - Resilient Seat, Short Pattern Fluid Treated Sewage Effluent Size(s) Φ1500 and Φ1800 Temp. (Deg C) Max.: 45 ° C Min.: 4° C Normal NA Flow Operation NA Connecting Pipe material Carbon Steel Pressure Rating (Bar) 25 Design Design/Manufacturing Standard BS EN 593 / AWWA C504 Face to Face Dimension standard EN 558 Flange Drilling Standard EN 1092-2 Type of connection Flanged, RF Type of Disc Design Double Eccentric Function/Operation Isolation (On/off) Electrical actuator with manual override Valve Mode of Gearbox with handwheel, square stem Operation cap, Seat Design Resilient seated (Replaceable) Flow Direction Bi-Directional Material of Construction Body Ductile Iron ASTM A536 Disc Ductile Iron ASTM A536 Disc pins Stainless Steel, Gr 316L Disc seating edge Stainless Steel, Gr 316L Shaft Duplex Stainless steel (1.4462) Shaft bearing Bronze / PTFE composite Seal Ring PTFE or equivalent O Ring EPDM, ASTM D2000 Fasteners Stainless Steel, Gr 316L Gland Bronze Extension Spindle Stainless Steel, Gr 316L Handwheel Ductile Iron ASTM A536 Gear Box Cast Iron, ASTM A126
Coating (Body) Inside & Outside Fusion bonded pure
Internal/External epoxy resin with dry film, 300µm thick
Coating (Disc) EPDM, ASTM D2000
Detailed material takeoff from To be filled by Vendor/Contractor manufacturer attached (Yes/No) Codes & Standards /Testing/ Certification Pressure test & Leakage test API 6D/ ISO 14313 Leakage Class EN 12266, A Material certification BS EN 10204 TYP. 3.1 Marking API 6D/ ISO 14313
Note:
1.The butterfly valves shall be equipped with disc drive actuators meeting AWWA C504 design equivalent BS EN standards requirements. Disc drive actuators shall be self- locking, high mechanical advantage to ensure low input efforts to reduce water hammer and could be directly mounted on top of the butterfly valve. 2. The butterfly valves shall be rated for zero-leakage (drip-tight) closure. Valve seats shall be designed to be leak-tight in both directions at differential pressures up to, and including, the rated pressure of the valve class. 3. The vendor shall confirm the compatibility of the material with respect to the fluid service. 4. All valves that are operated by actuators are controlled by SCADA. 4. DATA SHEET FOR ELECTRIC ACTUATOR Description Specification Vendor's Confirmation General Data To be filled by Manufacturer Vendor/Contractor To be filled by Model Number Vendor/Contractor To be filled by Vendor/Contractor as per the Tag P&ID drawing
Type Electric Actuated
Application Valve Operator (ON/OFF) Mounting Pedestal Torque Rating Note-6 To be filled by Output RPM Vendor/Contractor Noise level 75 dB at 1 m DN700: 147 Second Open & Close Time DN1000: 202 Second Note 7 Components Induction, totally enclosed, Motor insulation as per IEC 85, class F Gearing Oil Bath Over Ride Manual Handwheel Limit Switch On close and Open positions Torque Switch At end of travel Position Feed Back Transmitter or Mechanical Position indicator Visual Local - Off - Remote selector Yes switch (Yes/No) Mechanically and electrically Reversing Contractor interlocked reversing contactors for ON-OFF duty
Push Buttons (Open - Stop - Yes
Close - Reset) (Yes/No) Material of Construction Housing ASTM A 126 Bearing Bronze, ASTM B438 Rack Nickel - Steel ASTM B783 Gear Nickel - Steel ASTM B783 Screw Stainless Steel, Gr 316 Wedge Stainless Steel, Gr 316 O-Ring EPDM Top Cover Cast Iron, ASTM A126 Motor data Rated Voltage 400 V Phase 3 Supply Frequency (Hz) 60 Service factor 1.2 Starter Type Integrated Max. Ambient Temperature (°C) 50 IP Rating IP 68 Overload Protection Note-5
Note: 1. Each actuator shall have a hand wheel fitted on it for emergency operation. The hand wheel shall be designed such that it is declutched automatically when the power supply to the motor is restored. The hand wheel engaging lever shall give trouble free performance under repeated operation and limit the force not to exceed 250 N. 2. Actuator shall be designed for mounting in any position without lubricant leakage or other operational difficulty. 3. Each actuator shall have a local position indicator to indicate 0 to 100% of travel. Positional unit measurement shall be done using absolute encoders. 4. Internal wiring and limit switch contact development diagram for the actuators ordered shall be furnished. 5. Thermal overload relay shall be provided in addition to thermostats embedded in motor winding. Overload relay and thermostats shall be connected in control circuit to trip actuator in case of overload. OLR set value shall be mentioned in wiring diagram. 6. Manufacturer/Contractor shall be responsible for correctly sizing the actuators based on process conditions. The manufacturer shall size actuator for maximum torque required to operate the valve when subject to the conditions with full design pressure differential and the worst-case design temperature. 7. The Given “closing time, i.e.; travel time of disc from 90° position to 0°” is as per manufacturer. The preliminary assessment shows that the closing time Tc ˃ 2L/c i.e.; gradual closing. However, actual Lengthen or shortening of closure time in the field shall be studied in the surge analysis. 5. CHECK VALVE (NON-SLAM TILTING TYPE) Description Specification Vendor's Confirmation General Data To be filled by Manufacturer Vendor/Contractor To be filled by Model Number Vendor/Contractor To be filled by Vendor/Contractor as per Valve Tag the P&ID drawing
Check Valve (Non-Slam
Valve Type Tilting) Fluid Treated Sewage Effluent Size(s) Φ800 Connecting Pipe material Carbon Steel Pressure Rating (Bar) 10, and 25 Design Design/Manufacturing Standard EN 1074, Part 1 Face to Face Dimension standard EN 558 Flange Drilling Standard EN 1092-2 Type of connection Flanged, RF Material of Construction Body Ductile Iron ASTM A536
Internal body Zinc free bronze
Valve disc/valve ring Stainless Steel, Gr 316L
Guiding stem Stainless Steel, Gr 316L Spring Stainless Steel, Gr 316L Guiding Bush Stainless Steel, Gr 316 Inside & Outside Fusion Coating (Body) bonded pure epoxy resin Internal/External with dry film, 300µm thick
Codes & Standards /Testing/ Certification
Pressure test & Leakage test API 6D/ ISO 14313 Leakage Class EN 12266, A Material certification BS EN 10204 TYP. 3.1 Marking API 6D/ ISO 14313 Note: 1. The vendor shall confirm the compatibility of the material with respect to the fluid service.
