EM 02 EOPD and HOPD VALVE

2.1.0. Butterfly Valves:

Butterfly valves shall be of flanged construction and shall be complete with actuating
mechanism, matching counter flanging, bolts, nuts, gaskets, lifting lugs, sole plate for
supporting feet in the valve body etc. The butterfly valves shall be supplied from such
manufacturers who have supplied at least two (2) nos of butterfly valves of size 2000mm NB
and above which are in successful operation for at least two (2) years as on date of bid
opening.

Bidders shall furnish this information along with the bid.

2.1.1. DESIGN / CONSTRUCTION / MATERIALS PARTICULARS

The valves shall be designed for the design pressure / temperature as specified and in
accordance with IS13095/BS5155.

The vales shall be suitable for installation in any position (horizontal / vertical etc.).

All valve components and accessories of the same type shall be perfectly identical in size and
material so as to guarantee interchangeability of the parts.

This specification is valid also for the spare parts.

The actuator-operated valves shall be designed on the basis of the following prescriptions.
The internal parts shall be suitable to support the stresses due to the actuator, the
valve-actuator unit shall be suitably stiff so as not to cause vibrations, misalignments, etc.
All flanged ends shall comply with the standard specified.

The valve flanges shall be flat faced.

The bidder shall furnish the coefficient of capacity of each valve (CV in metric units) and the
characteristic curves.

Necessary shaft seal shall be provided and adequately designed to ensure no leakage across
the seal. This seal shall be designed so that they will allow replacement without removal of
the valve shaft.

The operating mechanism shall be mounted directly on or supported from the valve
body.

The Sealing ring on the disk shall be continuous type and easily replaceable.

Rubber seal shall be fitted on the periphery of the disc by clamping between the disc and
clamping ring. The seal design shall be T type and shall be held in machined grooves on the
disc and clamping ring. Seal design with clamping bolts passing through seal shall not be
acceptable.

The shaft shall be solid type and shall pivot on bushings. Bushings/sleeve type bearings
shall be contained in the hub of valve body.

The material of bearing shall be self-lubricated type with low coefficient of friction that does
not have any harmful effect on water and on valve components. Bearing shall be provided
beyond the shaft seal. The housing for this bearing shall be rigidly attached to the valve body.

The minimum length of the disk hubs shall be at least 1.5 the diameter of the shaft or
of the stems.

The shaft shall be connected to the disk through keys or taper pins or screws of stainless
steel. The connections shall be designed so as to avoid looseness during the operation;
moreover, they shall be provided with suitable disassembling systems. The design of the
shaft shall be such that it will safely sustain maximum differential pressure across the closed
 valve. The shaft and any key (taper pin or other) for transmitting the torque between shaft and
disk shall be capable of with standing the maximum torque required to operate the vale.

The disc shall rotate from the full open to the tight shut position. The disc shall be contoured
to ensure the least possible resistance to flow and shall be suitable for throttling operation.
While the disc is in the throttled position, valve shall not create any noise or vibration.

All butterfly valves shall have permanent arrow inscription on the valve body indicating
direction of flow. All valves shall be complete with:-graduated position indicator (located in a
visible place for the operation).Adjustable mechanical stop limiting devices to prevent over
travel of valve disk in open and closed position.

Valves shall have integrally cast supporting feet.

Actuators operated valves

Actuators will be with Limit and Torque switches for either end of travel for control and
interlocking purpose.

The characteristics of the actuators to be located on the valves are indicated in the
actuators specification.

Should the actuator be located on the control column, all connecting accessories shall be
supplied (extensions, joints, articulations, etc.). The valves 350Nb and above shall also be
provided with hand wheel drive arrangement suitable for manual operation. Manual operation
of valve shall be through worm and gear arrangement having totally enclosed gearing with
hand wheel diameter and gear ratio designed to meet the required operating torque. It shall
be designed to hold the valve disk in intermediate position between full open and full closed
position without creeping or fluttering. Adjustable stops shall be provided to prevent over
travel in either direction.

Limit and torque switches shall be enclosed in water tight enclosures along with
suitable space heaters.

2.1.2. MATERIALS / DESIGN DETAIL

Materials, design and other specific requirements of various categories of BF valves

shall be as indicated below.

Sl. No. Description Requirement.

a) Design As per IS 13095/ BS 5155
b) Type Double flanged
c) Material
i) Body and Disc Cast steel grade ASTM-A 276 74 d
Gr.WCB or SG Iron as per IS 1865 gr.
500/7
iii) Shaft Stainless steel AISI: 431
iv) Body Seat Monel 60 integral
v) Disc Seat EPDM
vi) Bearing PTFE LINED ST.ST.
vii) Testing AWWA-C-504/ IS
 viii) Other Requirement Tight shut off

2.1.3. SPECIFIC PERFORMANCE GUARANTEE

For the rubber seated valves, the bidder shall guarantee that in the closed position and
with a disc differential pressure as specified the valves shall be water tight.

The bidder shall guarantee that the operating mechanism shall open and close the valve
under the specified maximum differential pressure within the time specified.

The valve shall be suitable for frequent operation during initial commissioning operation after
a long period of inactivity.

2.1.3.1 MARKING

The mark stated by the Employer in the Material Request shall be printed on the body
of all valves and relevant accessories (control columns and relevant connecting elements to
the valve, counter flanges, valves for the auxiliary control if separately supplied, etc.).

The face of each hand wheel shall be clearly marked "Open" and "Shut" with arrows
indicating the direction of rotation to which they refer. Each handwheel shall also be fitted with
a circular name plate indicating the service for which the valve is intended and valve tag
number. The name plates shall be engraved in black lettering.

Each spare part shall be individually marked with metal plates suitably punched for an
easy identification.

2.1.4. TESTING AND INSPECTION

All valves shall be checked for correctness in respect of flange details as specified.
The valves shall be tested as per the requirement of AWWA C-504 (latest version)/IS.Proof of
design-tested valve shall not be supplied for the project.

For cast construction : Body and Disc shall be subjected to MPI/LPI and shaft shall be
subjected to UT and LPI.

For Fabricated Construction: All Butt welds having thickness 20mm and above shall be
subjected to Radiography and stress relieving. Only qualified welders shall be used for the
purpose of carrying out welding. Shaft shall be subjected to UT and LPI.

Site Test

The valves shall be tested at site for opening and closing time, valve operation etc. The valve
should operate without any flutter, noise, and vibration.

2.2. ACTUATORS FOR BUTTERFLY VALVES

2.2.1. DESIGN REQUIREMENTS:

Electric actuators shall essentially consist of electric motors, limit switches, hand wheel and
gear trains, mechanical position indicators, internal wiring and terminal block.

The electrical actuator assembly inclusive of drive motor and unit switches compartment shall
conform to IP 55 degree of protection.

Actuators shall be sized so as to open / close the valve at the rated speed against the design
differential pressure at 90% of the nominal voltage.

Lost motion hammer blow feature shall be provided for seating / unseating the valve when the
operating torque exceeds 11 kg/m.
 Operators shall be designed to be self locking (i.e. maintains the stem position) upon loss of
electric power supply.

Motors shall be installed on the operator prior to shipment to the valve manufacturer.

Actuators shall be provided with lifting lugs for handling it along with the bonnet. Actuator
assembly shall have all metal gear trains.

Operators shall be flange mounted on the valve bonnet. Welding of operators onto
bonnets is not permitted.

All actuators shall be either Auma or Rotork or employer approved equal.

2.2.2. OPERATING SPEED

All actuators shall have operating speeds as per the manufacturer's standard.
However, this shall meet operating requirement of the system. Actuator operating times
(opening and closing) shall be furnished with actuator details.

SERVICE CONDITIONS

i. The actuator shall be suitable for operation in a hot, humid and tropical atmosphere.
ii. Unless otherwise stated in the equipment specification, the ambient air temperature
shall be taken as 50 dg. C, relative humidity 100% and mean sea level less than 1000
meters.

2.2.3.RATING
The actuator shall be designed for operation on a 415 V + 10%, 3-Phase 50 Hz + 5%
solidly grounded system. The combined voltage & frequency variation shall be +/- 10%. The
control circuit voltage shall be 240/110 V A.C. or 220V D.C.

The actuator shall be rated for three successive open-close operation of the valve or 15
minutes, whichever is longer.

The normal torque rating of each drive unit shall have adequate margin and at least
equal to theoretical brake torque required to drive the equipment under full load, including all
losses in speed reducers and power transmission.

The drive shall take into account valve operating speeds and differential and static
pressures required for the service. The bidder shall select operating speeds and design
pressure to satisfy requirements of the equipment furnished and acceptable to the Employer.
Motor actuator assemblies shall have all metal gear trains. Fibre gears are not acceptable.

2.2.4. PERFORMANCE

The actuator shall open and close the valve completely and make lead-tight valve
close, without jamming.
The actuator shall attain full speed operation before valve load is encountered
and impart an unseating blow to start the valve in motion (hammer blow effect).
The actuator shall operate the valve stem at standard stem speed and shall
function against design differential pressure across the valve seat.
The motor reduction gearing shall be sufficient to lock the shaft when the motor
is de energized and prevent drift from torque switch spring pressure.
The entire mechanism shall withstand any shock resulting from closing with
improper setting of limit switches or from lodging of foreign matter under the valve
seat.

2.2.5. SPECIFIC REQUIREMENT

2.2.5.1 Construction
 The actuator shall essentially comprise of the drive motor, torque/limit switches, gear
train, clutch, hand wheel, position indicator / transmitter, space heater and internal wiring. The
actuator enclosure shall be totally enclosed, dust tight, whether proof suitable for outdoor use
without necessity of any canopy. All electrical equipment, accessories and wiring shall be
provided with tropical finish to prevent fungus growth.The actuator shall be designed for
mounting in any position without any lubricant leakage or operating difficult.

2.2.5.2 Motor Drive

The drive motor shall conform to sub-section E2 of this specification.

The drive motor shall be three phase, 415V, squirrel cage, induction machine
with class B insulation and IPW-55 enclosure, totally enclosed and self ventilated and
designed for high torque low inertia and reversing service suitable for operation at 50 deg. C
ambient temperature.The motor shall be designed for full voltage direct on-line start, with
starting current limited to 6 times full-load current.

All motors shall have TEFC enclosures with space heaters to maintain the internal
temperature above dew point when the motor is idle. Space heaters shall be rated for 240V
AC. The motors shall be capable of operating the valve against the maximum load on the
valve disc. with drive bearings in dry and dirty condition. Each motor shall be provided with
two direct temperature-sensing thermostats to prevent thermal overload. All motors shall have
O-ring seals to provide complete environmental protection when the motor is idle. Earthing
terminals shall be provided on either side of the motor. Double shielded grease pre-
lubricated, regreasble, antifriction bearings having a minimum life rating of 1,00,000 hours
shall be furnished.

Limit switch
2.2.5.3. Position Limit Switches:

Each actuator shall have rotary drum position limit switches, two (2) for open and
two (2) for close position, each with adjustable setting between fully open and fully close
positions. Each rotary drum position limit switch shall have two normally closed (NC) and two
normally open (NO) independent contacts. The adjusting mechanism for the limit switches
shall be easily accessible.

2.2.5.4. Torque limit switches:

Each actuator shall have two torque limit switches with suitable arrangement to limit
the opening / closing thrust. The torque switch, actuated by the torque clutch when the valve
is restricted during opening / closing shall stop the motor thereby protecting the motor from
overloading torque. The torque switches shall be set as near as possible to the pull out torque
of the motor without damaging the valve of the operation.Each torque switch shall have two
normally open (NO) and two normally close (NC) independent contacts. The torque limit
switch adjusting mechanism shall be easily accessible.Limit switches along with all necessary
electrical wiring shall be housed in a weather proof NEMA-3 enclosure and shall have
gasketted cover and space heater to maintain the temprature above dew point. Each torque /
position limit switch shall have 2 No + 2 NC potential free contacts. Contacts shall be rated to
make and carry continuously 10 A at 110 V AC and 0.5A (inductive) 220 V DC.

Manual operation: All actuators shall have mechanically independent manual drive
arrangement with hand wheel and motor declutching mechanism. The manual drive shall be
provided with clutch and gearing as required to limit hand wheel effort to 25 kgt maximum
along with suitable latch and locking arrangement to keep the hand wheel in engaged
position using manual operation.The hand wheel shall disengage automatically during motor
operation.

Position indicator/Transmitter: All actuators shall have one (1) built-in local position
indicator for 0-100 % travel. All actuators shall be provided with mechanical 3-point dial
position indicators. Rising steam valve shall additionally have visual position indication
through plastic stem covers. Where required, valves shall be provided with continuous remote
 position indicators of the potentiometric type. The available voltage sources for the
potentiometric position transducers are 220V DC and 240 V AC. The tranducer shall be
suitable for stablished 4-20 mA current signal. The associated wiring for the transducers shall
be housed in the limit switch compartment.

2.2.5.5. Space Heater: A space heater shall be included in the limit switch compartment suitable for
240 V AC, 50 Hz supply 220 V DC.

2.2.5.6.Wiring: All electrical devices shall be wired up to and terminated in a terminal box. The
internal wiring shall be of sufficient size for the power rating involved but no case less than 1.5mm
copper. All wiring shall be identified at both ends with ferrules. Internal wiring diagram shall be neatly
pasted on the rear side of the terminal box cover. Motor power, heater and all control wiring shall be
wired at shop to suitably rated master terminal blocks located within the limit switch compartment. All
internal wiring shall be of 650/1100 V grade flexible standard copper conductor cables with tropical
fungicidal treatment and the insulation shall be flame resistant. The limit switch terminals should be
capable of terminating two nos. 2.5 mm copper cable.Terminal boxes shall be provided with
removable undrilled gland plates to terminate following sizes of cable.

. I) 1 no. - 14 core 2.52 (Cu)

ii) 1 no. -10 cores - do -

iii) 1 no. - 2 pair

iv) 1 no. - 10 pair

v) 1 no. - Power cable

2.2.5.7. Terminal Box

Actuator terminal box shall be suitable to receive and terminate the following cables:

a) 1 No. power cable details of this shall be intimated later.

b) 3 Nos. 19 C x 2.5 copper conductor PVC insulated unarmoured control

cable.
Actuator terminal box shall be provided with a removable front cover plate, and an undrilled
detachable gland plate.

Data to be furnished: Motor data sheet for each type of actuator shall be furnished along with internal
wiring diagram, suggested control schematic and torque / limit switch contact development.