WAT-2019-004 - Air Scour Valves and Actuators

TECHNICAL SPECIFICATIONS
Air Scour Valve and Actuator Replacement
Technical Specifications
Feura Bush Water Treatment Plant




Background:

Water treatment plant administration has identified the need to replace a number of valves and electric motorized operators throughout the facility. At the end of useful life expectancy, each of the existing Butterfly Valves (BFVs) are in excess of 40 years old. Administrative staff has witnessed and recommends replacement due to valve seat degradation from differing factors such as; scaling, tuberculation, chemical infiltration and on seat duty cycles, that have compromised the “bubble tight” seal of the valve. Due to differing size range and location of the BFVs as well as a price point in excess of 50% in attempting seat repair or replacement, it is logical to begin a valve replacement program, in a prioritized manner, encompassing each of the process areas of the facility.
    
In addition to restoring valve performance, each electric motorized valve operator is of an obsolete vintage and no longer supported by the manufacturer. Utilized as remote, motorized actuation devices throughout the flow train at the facility, each of the original Italian manufactured Keystone BIFFI QTC valve actuators, are of a 1996 vintage. These devices have begun to fail at many of the contacts internal to the electronic micro switches associated with digital status related to open, close, and remote feedback of the actuator. Staff performs “hand wheel” operation of many of these actuators, based upon the inability of the device to operate electrically, due to differing failure modes at each motorized valve actuator.

Scope:

This specification defines the parameters in the purchase of seven (7) Butterfly Valves and Electric Motorized Actuators in order to revitalize the air scour process and fortify the backwash process at the treatment facility. The purchase shall include seven (7) remote actuator operation stations providing full localized operation from the ground or platform below the actuator. This purchase will include American Water Works Association (AWWA) approved twelve (12”) inch butterfly valves and appropriately sized electronic actuators as integral units to be constructed/joined and calibrated by the vendor before being delivered to the Albany Department of Water and Water Supply (AWD). 

This specification covers the design, manufacture and testing of AWWA Class 150B and AWWA Class 250B butterfly valves. Electric Motorized Actuators shall be furnished in accordance with AWWA C542 for powered actuators and factory tested (limits calibrated) on the supplied production valve.

This specification encompasses purchasing of defined and specified materials and or devices only and does not include the purchase of installation. Installation will be performed in house on a scheduled, prioritized basis. 

Butterfly Valves (BFVs):

Standards, Approvals and Verifications:
 

1. The valves shall be designed, manufactured and tested in accordance with AWWA Standards ANSI/AWWA C504 and C516
2. The valves shall be certified to NSF/ANSI 61 and safe for potable/drinking water systems and components. Valves and components shall be certified to be lead free in accordance with NSF/ANSI 61, Annex G.
3. Manufacturer shall have quality management certified to ISO 9001 by an accredited certifying body.

1. Valve shafts shall be of the through type design and fastened to the disc utilizing stainless steel components.
2. Disc shall be of the solid type and constructed as to not obstruct flow in the open position.
3. Resilient seats shall be located either “on body’ or “on disc” and shall provide a 360⁰ continuous uninterrupted seating surface. Resilient seats shall be field replaceable without the use of injection epoxy, syringes and pressure vessels to replace or adjust. In the event of an “on disc” submittal, seats shall be mechanically retained with stainless steel retaining rings and stainless steel cap screws which shall pass through both the resilient seat and the retaining ring.
4. Sleeve bearings shall be self-lubricating.
5. Shaft seals shall be of the V or O ring type and shall be replaceable.
6. Butterfly Valves shall be shall be Val-Matic® Series #2000 as manufactured by Val-Matic® Valve &Mfg. Corporation, Elmhurst, IL. USA or approved equal.      

1. Flanged end connections shall fully conform with ANSI B16.1 for Class 125, Class 250 or AWWA C207 Class D. Flanges shall be flat faced.
2. Butterfly valves shall be class 150B in this application.

1. Valve bodies shall be constructed of Class B gray iron, ASTM A126 or Grade 65-45-12 ductile iron, ASTM A536. Class 250B valve bodies shall be ASTM A536 Grade 65-45-12 ductile iron.
2. Valve discs shall be constructed of ASTM A536 Grade 65-45-12 ductile iron.
3. Shafts shall be ASTM A276 Type 304 or ASTM A564, Type 630 Stainless Steel.
4. Hardware: all hardware included shall be Type 316 Stainless Steel.

1. All coatings utilized on the interior or exterior of the valve body shall meet NSF/ANSI 61 and conform to all safety standards for potable drinking water and associated systems.

1. Electric Motorized Actuation shall be provided as specified.
2. Motorized actuators shall be furnished in accordance with AWWA C542 for Power Actuators and factory tested on the production valve. The motor actuator assembly shall be designed for open/close service with a minimum operating time of 60 seconds.
3. The actuator shall be furnished with on board position indication, independently adjustable limit switches and adjustable torque sensing or switches to provide protection to the actuator and valve.
4. Electric actuator should be equipped with separate 4-20 analog input and output for position control and or position indication.
5. Actuators shall be powered via 208VAC 3 Phase power. The motor shall be of a “Totally Enclosed Non Ventilated” design. Actuator motor and gearing shall be appropriately designed to allow motor start and re-start in the same direction against maximum load without the aid of hammer-blow or other lost motion devices.
6. In order to prevent condensation, a heater must be installed internal to the actuator suitable for continuous operation. If connection compartments are separate, anti-condensation heaters must be included wherever water infiltration might cause damage to the actuator.   
7. Terminal compartments for customer connections shall be isolated and safe in a fashion in which conductors, connections, and other internal wiring can be troubleshot without disconnecting power from the actuator.
8. In order to maintain integrity of the enclosure, configuration of all actuator parameters shall be accomplished without removing covers or any connection related to the device. Settings shall be made through external pushbutton or touch screen and include blue tooth connections for laptops, mobile phones or other handheld programming devices. Settings shall be easily readable from a local LCD or similar display.
9. Actuator shall include a local position indicator with display from fully open to fully closed in 1% increments. The display shall also include on board lights displaying a full open or full closed condition.
10. An integral hand wheel and de-clutching mechanism shall be included with the actuator. Hand wheel shall be easily engaged regardless of torque on the valve. Motor failure will not compromise the use of the hand wheel for manual operation. 
11. Valve actuator shall be sized according to production valve manufacturers published torque specifications and recommended install application. (Air Scour, Non-liquid)
12. Actuators shall be supplied with the required mounting adaptation mounting brackets and be delivered pre mounted, to the production valve, as a singular device, calibrated and ready for installation.     
13. Actuators shall be Model SQ12.2/AC01.2/RCS01.1 as manufactured by AUMA Actuators Incorporated, Canonsburg, PA USA or approved equal.

1. The actuator shall be sealed and water tight to NEMA 4X/6 standards and submersible to IP 68-8 (26 feet for 96 hours) in accordance with EN 60529. During submersion the actuator must be operable at least 10 times.
2. Gear case shall be of cast iron construction.
3. All adaptation and mounting hardware shall be provided with the actuator. All fasteners shall be Stainless Steel. All mounting and calibrations shall be performed at the factory with NO adaptation or mounting modifications of the valve and actuator in the field.