Technical Specifications

Valves

Section 15101 Valves Part 1 General

Reference Standards A Applicable standards referred to in this section AWWA C500 AWWA C509 BS 1400 BS 1452 BS 4504 BS 5153 BS 5163 DIN 1693 DIN 3352 DIN 17440 JIS B 2031 JIS B 2032 JIS B 2051 JIS B 2062 JIS B 2063 JIS B 2064 JIS B 2071

1.03

System Description A Valves shall be capable of extended and continuous operation under the specified conditions and at the specified operating pressure. The manufacturer shall have current ISO 9001 accreditation.

Part 2 Products
2.01 Valves and Appurtenances - General A All valves shall be suitable for use with water temperature up to 50o 60o C and in climatic and soil conditions encountered in the country of installation. Valves shall be of the same pressure rating as the adjoining pipe, but with a minimum rating of 10 16 bar. Unless otherwise specified, all valves and appurtenances shall be externally and internally fusion bonded epoxy coated using electrostatic/ fluidised bed process conforming to DIN 30766 or approved equivalent. The coating shall have a minimum thickness of 300 microns, be Holiday-free, non-toxic and colour code RAL 5015. Before application of epoxy coating the surface shall be sand blasted to a minimum SA 2.5 and air blown to ensure a good bond with the epoxy coating. A certificate verifying the suitability of the epoxy coating for use with drinking water is required from the manufacturer, endorsed by the National Water Council, UK, or a similar independent national body acceptable to the Engineer. Valves shall be supplied complete with flanges, gaskets and stainless steel nuts, bolts, and washers. Flange

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gaskets shall be of the metal reinforced type. Nuts, bolts, screws and fittings shall be of stainless steel with 2 washers per bolt. Bolt length shall be such that after the joints are made-up, the bolt protrudes through the nut but not more than 12 mm. Unless otherwise detailed or specified here-in, valves shall be supplied complete with stainless steel extension spindles and appurtenances such that the square-nut operator is within 300 mm of the underside of the valve chamber cover slab. Where required, special couplings shall be incorporated to absorb the weight of the extension spindle at no extra cost to the Employer. Stem cap of all valves and square nut operator in case of extension spindles shall be in accordance with BS 5163. One extra stem cap to be supplied for each valve at no extra cost to the Employer. Unless otherwise specified here-in, all attaching hardware of all valves and appurtenances including the nuts, bolts and washers for flanged valves shall be stainless steel. B Marking of valves shall include the; manufacturing standard; manufacturers name or trademark; nominal diameter (N.D.) in mm; pressure rating in bars; an individual serial number which relates directly to the manufacturers test certificate; and month and year of manufacture. All gate and butterfly valves shall be clockwise closing and the direction of opening and closing shall be clearly marked. Position indicators shall be provided on all gate and butterfly valves and shall have adjustable end limit stops at both open and closed end positions to prevent damage by excessive operating force. The maximum effort required to operate the valve against the maximum unbalanced head applied at the circumference of the handwheel or end of the tee-key shall not exceed 15 kg and where necessary gearing shall be provided as specified to achieve this. Handwheels shall be provided for all valves when installed above ground, when operation is within reach. Valves installed deeper than 300 mm shall be provided with an extension spindle and Tee-key. Valves installed out of reach above ground shall be provided with chain drive or remote control drive as shown or specified. All gate and butterfly valves shall be designed to provide 100 percent water tight shut off at all specified pressures and suitable for installation of electrical actuators when required. Line valves of 300 mm diameter and smaller shall be double flanged gate valves, unless otherwise indicated. Butterfly valves shall be used as line valves for sizes larger than 300 mm diameter and shall be flanged. Where flanges are required they shall be drilled to PN 16 unless specified or directed otherwise. Valve packing shall be manufactured from pure TFE/PTFE fibres/filament in square plait or multi lock braid construction and shall be lubricated with a suspensoid of TFE/PTFE before braiding and an inert softener/lubricant.

2.02

Gate Valves A Gate Valves shall conform to the provisions of AWWA C509; JIS B 2062; DIN 3352 Part 4A & B or approved equivalent and as further specified herein. Valves shall be inside screw, non-rising stem, clockwise closing, wedge, gate valves suitable for underground use and flow in both directions. Valves pressure rating shall be equal to, or greater than the adjoining pipe or fitting but a minimum of 10 16 bar. Valves shall be designed for the Closed End Test and shall be of resilient seal design with bolted bonnet connection and straight-through port. Wedges shall be low clearance - guided in the body and shall have an inner core of ductile iron GGG500 conforming to DIN 1693 or approved equivalent. They shall be encapsulated with a synthetic EPDM rubber covering on the inside and outside by vulcanising. The rubber covering shall have a minimum thickness of not less than 2.5 mm on both flow sides and 2.0 mm on sealing surfaces with no body-metal exposed. EPDM wedge rubber shall be approved to be used for potable water and be selected to meet the chemical properties and

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temperatures of the fluid being handled by the valves. B Stems shall be non-rising and manufactured of stainless steel 1.4462 to DIN 17440 or approved equivalent. Stem threads shall be of the rolled type. Sealings and bearings shall be corrosion proof and maintenance-free and shall be designed in the form of a series of O - rings of synthetic rubber. Stem bearing gap shall be sealed against entry of dust by a wiper ring. Stem sealing should be replaced when required. Stem nuts shall be of zinc-free bronze 2.1050.01 to BS 1400 CT 1-C or approved equivalent. The body and bonnet shall be ductile iron GGG 500/400 to DIN 1693 or approved equivalent and shall be internally and externally fusion bonded epoxy coated as specified here-in. Prior to assembly, the entire valve body and bonnet shall be holiday tested internally and externally at not less than 3.0 kV to DIN 30677 or approved equivalent. Manual operation shall be by handwheel or by Tee-key as shown on the Drawings. Gear operated valves shall be provided with operating nuts and Tee-keys as specified. Gear cases shall be totally enclosed and equipped with indicators to show valve position and designed for full differential pressure of 10 16 bars.

2.03

Butterfly Valves Not Used A Butterfly valves shall conform to one of the following standards: BS 5155; JIS B 2064; DIN 3354; AWWA C504 or ISO 5752 with a rating equal to, or greater than the adjoining pipe or fitting but with a minimum of 10 bar. They shall be double flanged, short body type with worm type manual operating gear with stem cap and shall be manufactured from the following materials: 1 body and flange : ductile iron/grey cast iron to BS 1452 Grade 260. 2 disc : aluminium bronze to B.S. 1400 AB2 3 internal body lining : EPDM rubber bonded to body by vulcanising. : min. thickness 18 mm for valves of diameter 10002000 mm : min. thickness 12 mm for valves of diameter 700-900 mm. : min. thickness 9 mm for those less than 700 mm. : temperature resistant to 100oC. : suitable for use with potable water. 4 shaft and gear spindle : stainless steel 1.4462 to DIN 17440. 5 shaft bearing : self lubricating type with EPDM O ring seals All the valves shall be of high reliability, of robust design and tropicalized in accordance to the worst prevailing ambient conditions. Valves shall be coated externally with blue colour (RAL 5015) non-toxic polyurethane to a minimum dry film thickness of 150 microns. All the valves shall be designed for no leakage under flow from either direction tested at a differential pressure across the seal of rated working pressure. Each valve shall be subject to a body pressure/leakage test of 1.5 times the design pressure before leaving the manufacturer's works. A certificate showing that any rubber lining used is non-toxic to potable water in accordance to international standards shall be obtained from an internationally recognised authority.

2.04

Toothed Vane Butterfly Valve A The valve shall comply as far as possible with BS 5155, JIS B 2064 or equivalent. The valve shall be designed and manufactured to operate properly under operating condition specified in the Particular Specification without subjecting any part of valve assembly to cavitation-induced damage or causing any noticeable vibration and noise

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of the valve and its appurtenances. The valve shall be designed to have essentially equal-percent characteristic with a valve opening. BUnless otherwise specified, the valve have a pressure rating, equal to, or greater than, the adjoining pipe and fittings but with a minimum of 10 bar, and shall be capable of withstanding an open position test pressure appropriate to the working pressure. The valve shall be metallic-seated tight-closure, toothed vane disc butterfly valve and shall be designed and manufactured to meet the design working pressure and the maximum flow velocity of 6 m/sec. C The valve shall be also designed and manufactured to have following features: 1 hydrodynamically designed, toothed vane to split up the flow stream and to reduce noise and cavitation effectively while providing precise flow control; 2 rangeability providing accurate and repeatable control over a wide range of flow rates. The valve body shall be double flanged and made of ductile cast iron conforming to JIS G 5502 FCD450-10, or equivalent. The shaft shall be made of Type 403 or 420J2 stainless steel.

EThe disc shall be designed to have integrally cast grooves which stabilise water flow through scattering the jet and reducing the occurrence and growth of cavitation. The disc shall be made of ductile cast iron conforming to JIS G 5502, FCD450-10. The body seat and disc seat shall be stainless steel and shall be chosen with consideration of anti-sticking even if there is repetitious operation. The stainless seat shall be securely bonded to the base metal of the body or the disc by integrated casting method. Mechanically clamped designs will not be accepted. The seat shall be tight-closure and its leakage amount shall be equal to, or less than, 100 ml/minute tested by the seat leakage inspection procedure. FUnless otherwise specified, the dimension of the valve shall be: 1 face-to-face dimension of the valve shall comply with BS 5155 or JIS B 2064; 2 dimensions, except thickness, and drilling of each flange of the valve shall comply with ISO 2531 PN16. 2.05 Butterfly Float Valve A Butterfly float valves to be used shall be designed to mechanically and automatically open and close according to the water level in the reservoir.

BButterfly float valves shall be the all stainless butterfly float valve. The valve shall consist of a rubber sheeted butterfly valve, gear unit, float and a connection rod to support the float. The gear unit shall be so designed to operate the butterfly valve between fully open and fully closed positions in the range of 45 degree vertical movement of the connection rod which shall be operated by a float. The gear unit shall be provided with a stopper to prevent the connection rod from movement exceeding 45 degree. The float shall have enough volume and weight to operate the valve gear unit. The operating level of the float shall be adjustable. The float shall be suspended with stainless steel (JIS G4303 SUS316) wire from the ceiling of the reservoir/tower so as to prevent the float from dropping off during low level water storage. C D The valve shall have flanged ends conforming to ISO 2531 PN 16. The material to be used for the construction shall be stainless steel, stainless steel castings or rubber. Materials of major parts are as follows;

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Valves

Valve body Valve disc Valve shaft Short pipes Connection rod Float 2.06 Air and Vacuum Valves A

: : : : : :

stainless steel, JIS G5121 SCS 13 stainless steel, JIS G5121 SCS13, rubber sheeted stainless steel, JIS G4303 SUS304 stainless steel, JIS G4303 SUS304 stainless steel, JIS G5121 SCS 14 stainless steel, JIS G4303 SUS 316

Air and vacuum valves shall be designed to discharge air during filling of pipelines, admit air during emptying of pipelines and discharge air accumulated at high points in pipelines during normal operation. For both double orifice air valves and single orifice air valves the material of construction shall be: 1 body/cover/dust cover :grey cast iron to BS 1452 grade 220 or approved material, 2 all working parts :bronze, stainless steel or other non-corroding material, 3 coating :shall be in accordance with the Particular Specifications. Detailed catalogues with drawings and graphs showing air inflow/outflow curves shall be submitted for approval. Valves shall be supplied with rubber gasket, stainless steel nuts, bolts and washers. Double orifice air valve shall combine both large and small orifices within one valve. The large orifice shall be sealed fully and automatically by a buoyant rigid ball. The chamber housing shall be designed to avoid premature closing of the valve by the air being discharged. Small orifices shall be sealed by a buoyant ball at all pressures above atmospheric, except when air accumulates in the valve chamber. Valve shall be double flanged drilled to BS 4504 PN 10 16 pattern and valve construction shall be without integral isolating valve. Valves shall be dynamic type and effective sealing pressure required at valve to give effective sealing shall be 0.1 bar. Single orifice air valve shall be of screw down type and of 25/50 mm size. Valves shall be supplied with gunmetal cock, gunmetal strap and stainless steel pipe.

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Air valves unless otherwise specifically indicated on the drawings shall be of the following type and size depending on the size of pipeline in which they are installed. Size of Pipe (mm) Nominal Size of Air Type of Air Valve Valve (mm) Body Size Flange Size Up to 200 25 Saddle Single orifice with an isolating cock, 25 mm BSP threaded male ferrule 250 300 60 80 Double orifice with flanged inlet and an isolating gate valve 400 - 600 100 100 Double orifice with flanged inlet and an isolating gate valve 800 - 1200 150 150 Double orifice with flange inlet and an isolating gate valve

2.07

Check Valves A Check valves shall be of lever and weight operated type to BS 5153 or other approved standard with cast iron body, bronze trim and rubber faced. Flanges shall be in accordance with BS 4504 and drilled to BS 4504 Pattern 10.

Part 3 Execution
A Valves shall be installed and commissioned in accordance with manufacturers instructions. The Contractor shall co-ordinate the valve requirements with those of the actuators and instrumentation to ensure compatibility of control interfacing and operations. All valves shall be tested to the appropriate test pressure at the manufacturers works, and shall be supported by a test certificate from the manufacturer. Work tests on all valves shall witnessed by an approved independent testing agency at no extra cost to the Employer. The Contractor shall supply the original manufacturers test certificate endorsed by the approved independent testing agency for each valve supplied. The certificate shall relate to the individual number cast on each valve and shall give the date of test. The manufacturer shall factory test each valve 600 mm or larger in diameter for performance, leakage and hydrostatic pressure in accordance with AWWA C500.

End of Part 15101

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