SECTION 15103 VALVES AND EXPANSION JOINTS FOR SEAWATER SERVICE

PART 1 - GENERAL 1.1 A. DESCRIPTION OF WORK This Section covers the design, materials, fabrication, testing, inspection, cleaning, and shop painting, of the following equipment for seawater service: 1. 2. 3. 4. 5. B. Large butterfly valves Expansion joints Blind flanges Slow closing air and vacuum valves (SCAVV) Miscellaneous valves and accessories

All labor, material, equipment, and laboratory services, if any, required to satisfy the requirements in this Section shall be provided by the Contractor unless stated otherwise. Related Work: 1. Section 02625: Glassfiber Reinforced Plastic Pipe (GRP) for Seawater Pipe Water Distribution System Basic Materials and Methods Mechanical

C.

2. Section 02713: 3. Section 15050: 1.2 A.

QUALITY ASSURANCE Codes and Standards: Design, material, fabrication, inspection and testing of all equipment shall, unless otherwise specified, be in accordance with the latest revisions of the applicable codes and standards of the below listed agencies. In the event of conflict between this specification and any codes or standards, the matter shall be brought to the MARAFIQ's attention for resolution. 1. 2. 3. 4. 5. I American Society for Testing and Materials (ASTM) American Society of Mechanical Engineers (ASME) American Gear Manufacturing Association (AGMA) Manufacturers Standards Society (MSS) nstrument Society of America (ISA)

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6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. B.

Steel Structures Painting Council (SSPC) American National Standard Institute (ANSI) Hydraulic Institute (HI) American Water Works Association (AWWA) American Iron & Steel Institute (AISI) American Welding Society (AWS) National Electrical Manufacturers Association (NEMA) Insulated Power Cable Engineer's Association (IPCEA) MARAFIQ Electric Code (RCEC) International Standards Organization (ISO) Institute of Electrical and Electronics Engineers (IEEE) Underwriters' Laboratories, Inc. (UL) Pipe Fabrication Institute (PFI)

Equipment and material meeting other standards, which ensure quality and safety equal to or higher than United States standards, regulations, and codes will also be acceptable, subject to the approval of the MARAFIQ. In these instances, the Contractor shall be required to demonstrate the equivalency of the standard(s), and shall furnish the MARAFIQ with one copy of the standard(s) used for the design and fabrication of the equipment. Factory Tests: 1. Factory tests of each large butterfly valve shall be in accordance with Section 5.0 of AWWA C-504. Torque switches and limit switches shall be tested in conjunction with the valve motor operators for full open and closed positions.

C.

2.

D.

Hydrostatic and leak test of each valve shall be done at 7.5 kg/cm2G except for large in-line butterfly valves on seawater supply and return lines which will be leak tested for 5 bar and 3 bar differential pressure respectively. Hydrostatic and leak test on large butterfly valves on the seawater supply line shall be done, considering bidirectional flow condition.

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1.3 A.

SUBMITTALS Product Data: Submit manufacturer's drawings and specification, load tables, dimensions and installation instructions for the product to be supplied. Detailed procedure for surface preparation, painting and paint types for all carbon steel or cast iron surfaces. Certified reports for all factory tests conducted. Sizing calculation for air release and air and vacuum valves based on system configuration. SITE CONDITIONS Equipment furnished in accordance with this specification should be suitable for seawater installation and operation. The seawater temperature will range from 22.9oC to 32.2oC. Table 1 lists the relevant chemical constituents and their concentration in the seawater at the worksite. OPERATING AND PERFORMANCE REQUIREMENTS Butterfly Valves: 1. Valves larger than 600 mm size shall be furnished with motor operators and manual override. Valves 600 mm and smaller shall be provided with gear operators. Valves up to 300 mm may be direct buried. All valves larger than 300 mm size shall be installed in concrete valve chambers. Disc drives for direct buried valves shall be supplied with extension stem and at-grade valve box. For manual operated valves installed in chambers, disc drive actuators shall be supplied with extension stem and a floor box for operation from above the valve pit. Each butterfly valve shall be capable of being individually opened and closed under pressure. Each butterfly valve shall be designed as an isolation valve to operate from full open to full closed position. Each butterfly valve shall have leak-tight shut-off characteristics. Valves on seawater supply line shall have leak-tight shut off characteristic under bidirectional flow condition. Specific Design Requirements:

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C. D.

1.4 A.

B. C.

1.5 A.

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6.

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a.

All large butterfly valves shall be designed to withstand 51 m of water shutoff pressure, 5.0 m vacuum, 42C temperature, and the seawater constituents shown in Table 1. Valves on the seawater supply line shall be designed under bidirectional flow condition. All large butterfly valves (rubber seated) shall be designed in accordance with AWWA Standard C-504 for short body valve construction at ratings corresponding to design pressure. Valves shall be furnished with flat faced flanges constructed and drilled in accordance with ANSI B16.1, Class 125 for sizes up to and including 2400 mm and AWWA C-207, Class D for sizes above 2400 mm. Motor operators shall be provided on butterfly valves larger than 600 mm size. Detailed requirements for the motor operators are specified in paragraph 2.4 of this specification. Accessories, such as expansion joints and blind flanges where furnished shall be compatible with the design requirements for the butterfly valves. In addition to the information contained in the attachments, the following requirements apply: (1) The valves shall be tight closing, butterfly type, constructed so that they will close tight and remain tight under all conditions, including periods when the operating mechanism has been disconnected from the valve shaft. These valves shall be provided with, through shafts and the disc shall rotate through approximately 90 degrees from full open to tight closure, mechanical stops shall be provided to govern rotation. For design purposes, both the inside and outside surfaces of the valves shall be considered to be immersed in seawater. Supports shall be provided as an integral part of each valve body for floor mounting. Each support shall be designed with four drilled holes to accept 38.1-mm anchor bolts. The inlet and outlet of each valve shall be designed with sufficient rigidity to minimize end distortion and to ensure proper mating with flanges of pipes and other equipment. Blind rubber-lined steel/cast iron flanges shall be provided with valves where valves are installed as line terminations for future system installations. These flanges shall be constructed and drilled in accordance with ANSI B16.1, Class 125 sizes up to an including 2400 mm and AWWA C207 Class D for sizes above 2400 mm. Rubber lining shall be continuous on the entire flat face surface and the entire flange outside circumferential edge surface. Exterior surface of the blind flanges shall, as a minimum, be provided with corrosion resistant protective coating.

b.

c.

d.

(2)

(3)

(4)

(5)

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(6)

Inline blind flanges and inline blank flanges, where provided, shall be constructed of fiberglass or aluminum bronze or monel material and drilled in accordance with ANSI B16.1, Class 125 for sizes up to 2400 mm.

TABLE 1 TYPICAL SEAWATER ANALYSIS Constituents 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Color Turbidity Conductivity pH Total Dissolved Solids Total Dissolved Oxygen Ammonia Calicum Iron, Total Magnesium Potassium Sodium Chloride Fluoride Nitrate Sulfate Alkalinity, Total Bicarbonate Alkalinity Phosphate Total Suspended Solids Silica Chloride Residual As *PCU *NTU(1) *micro mhos/cm @ 25C *Units TDS 02 NH4+ Ca++ Fe++, Fe+++ Mg++ K+ Na+ C1 F NO3SO4= CaCO3 CaCO3 HPO4= TSS SiO2 Cl2 Concentration (ppm) 5(2) 0.5 to 1.0(2) 57,000 -64,000 8.1 -8.3(2) 41,350 -46,400 3.5 -5.0 0.2 Ca++ 490 -560 0.01 1,500 -1,600 425 -650 11,700 -12,500 21,600 -23,500 F 1.5 <0.1 3,000 -3,200 120 -130 85 -95 <0.1 1.0 0.5 0.5 -0.7(3)

(1) NTU -Nephelometric Turbidity Units (2) Items are in units noted and not ppm. (3) After dosing chlorine at seawater pumphouse (SWPH) intake

B.

Slow Closing Air and Vacuum Valves: 1. Each slow closing air and vacuum valve shall be capable of being individually opened and closed under pressure or vacuum condition automatically. Specific Design Requirements: The air vent shall be a slow closing air and vacuum valve and shall provide continuous air removal during the system operation and shall relieve large quantities of air when the system is being filled.

2.

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a.

Slow closing air and vacuum valve shall open at any time the water level drops and the line pressure approaches atmospheric and immediately have full reentry flow of air into the pipe line before vacuum can form. The isolating butterfly valve shall be mounted at the bottom of the air and vacuum valves, to permit regular maintenance. Components of slow closing air and vacuum valves shall be designed to withstand 51 m of water shutoff pressure, 42oC temperature, and the seawater constituents shown in Table 1 of this Section. Slow closing air and vacuum valves shall be furnished with flat faced flanges constructed and drilled in accordance with ANSI B16.1, Class 125. The surge check mechanism shall be consistent with slow closing air and vacuum valves or shall be mounted on top of the isolating butterfly valve and shall eliminate critical shock condition in order to prevent the slow closing air and vacuum valves from creating a surge in the line by slamming shut, and fully reenter air into the pipe in case of line on the vacuum condition. Slow closing air and vacuum valve should not be considered as relief for shock conditions which develop elsewhere in the system. Slow closing air and vacuum valves shall be designed with sufficient rigidity to minimize end distortion and to ensure proper mating with flanges of pipes and other equipment.

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c.

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f.

g.

C.

Miscellaneous Valves: 1. Each valve shall be capable of being individually opened and closed under pressure with suitable operating system (e.g. motor operator, manual, automatic etc.). Valves for potable, process and reclaimed water services are covered under specification Section 02713. Specific Design Requirements: a. The valves shall be designed to withstand 51 m of water shutoff pressure, 42oC temperature, and the seawater constituents shown in Table 1 of this Section. The valves shall be furnished with flat faced flanges constructed and drilled in accordance with ANSI B16.1, Class 125.

2.

3.

b.

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c.

The valves shall be designed with sufficient rigidity to minimize end distortion and to ensure proper mating with flanges of pipes and other equipment. Air release valves (non-slow closing) shall provide continuous air removal during the system operation and shall relieve air when the system is being filled. The isolating valves shall be mounted at the bottom of the air release valve or associated with air release valve (non-slow closing), to permit regular maintenance. The air release valve (non-slow closing) should not be considered as relief for shock conditions which develop elsewhere in the system. Material specification for each valve are as follows: Type Sizes (mm) Globe 13 -400 13 -500 Air Vent 13 -300 (Non Slow Closing) Gate 13 -400 13 -25 PVC 13 -500 Description Aluminum Bronze Body Ball Aluminum Bronze Body Aluminum Bronze Body Aluminum Bronze Body Ball Body Butterfly Valve Aluminum Bronze Body Valve

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f.

g.

PART 2 - PRODUCTS 2.1 A. GENERAL The use of a manufacturer's name and model or catalog number is only for the purpose of establishing the standard of quality and general configuration desired. Other manufacturer's products may be submitted for approval by the MARAFIQ. Only upon submittal and subsequent written approval of the technical data shall these items be permitted. Whenever the term "in accordance with the manufacturer's specifications" is used, it shall mean in strict accordance with the manufacturer's printed direction. If those directions conflict with this specification, the matter shall be brought to the attention of the MARAFIQ for clarification prior to proceeding with the work. Materials and products used throughout the systems shall be new and free of defects and imperfections. MATERIALS The material requirements for the valves, slow closing air and vacuum valve, expansion joints, blind flanges and accessories are as follows:

B.

C.

2.2. B.

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Part Body Disc Seat Seat Retainer Shaft Expansion Joint Flat-face Gasket Flange Packing Float Spring Bearing Blind Flange & Blank Flange Drive Box Bolts/Nuts Isolation Ferrule C.

Material

ASTM and/or Other Designation

Aluminum Bronze (cast) ASTM B 148 CA 958 Aluminum Bronze ASTM B 148 CA 958 Rubber (EPDM) Aluminum Bronze ASTM B 169 CA 614 Monel K 500 ASTM B 169 CA 614 Rubber (EPDM) Rubber (EPDM) Aluminum Bronze ASTM B 148 CA 958 Rubber (EPDM) Aluminum Bronze ASTM B 171 C 630 Stainless Steel ASTM A 313 S 31600 Teflon with Fiberglass Backing Cast Iron or Carbon Steel Rubberlined (EPDM); FRP, Al-bronze Cast Iron or Carbon Steel Aluminum Bronze ASTM B 169 CA 614 Rubber (EPDM)

General Notes for material requirements: 1. 2. Aluminum-bronze shall be temper annealed per ASTM B 601. Welded aluminum bronze shall be stress relieved at 621o to 649oC for 1 hours for the first inch of thickness and 1/2 hour for each additional inch of thickness. No internal or external part, hardware or clamp shall contribute to the corrosion or galvanic attack and shall be as recommended and tested by the valve manufacturer and subject to approval of MARAFIQ.

3.

C.

Valve Disc: Valve discs shall be designed and tested in accordance with the requirements of AWWA C-504, Section 5.0. Valve Seat: Seats shall be of material specified and in accordance with the requirements of AWWA C-504-80 Section 3.5. Valve seats located in the valve body or on the valve disc shall be mechanically retained and shall be designed to permit field replacement. Valve Shaft and Bearings: 1. Shafts shall have sealing provisions to prevent seawater from entering the valve body shaft support area. The outside shaft surface will be in contact with seawater at approximately 1.6 m below the centerline of the handwheel. Valves shall be fitted with sleeve type bearings in the upper and lower body trunnion. A thrust collar shall be provided to take the weight of the disc.

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E.

2.

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3.

Materials for all bearing surfaces that may come in contact with seawater shall resist corrosion. Design of bearings and seals should provide long service-free life. However, when replacement of seals and bearings is required, this shall be accomplished from outside the valve, without removal of operator or decompression of the system.

4.

F.

All nuts, bolts and attachments are to be provided by Contractor. All nuts, bolts and washers shall be of aluminum-bronze noncorrosive material in submerged quiescent seawater service. Isolation ferrules shall be designed to prevent direct contact galvanic action between al-bronze material and any steel surfaces. Testing documentation to verify material suitability and compatibility shall be submitted specifically where hardware will retain valve seat seal. VALVE ACCESSORIES Valve accessories shall be provided as specified herein and shall be supplied completely assembled and properly adjusted in the factory. Valve Drive: Each valve shall be designed with a gear box using a worm gear drive system, which is operated with a maximum 45 cm diameter handwheel and for valves larger than 600 mm size, an output shaft for adapting a motor operator. The handwheel and gear ratio shall be designed to enable the valve to open or close with a minimum of effort and without the necessity of using levers against a differential pressure equal to the valve design pressure and in accordance with AWWA C-504, Section 3.8. 1. Each 2900 mm and larger valve shall include a 50.8 mm wrench nut connection on the handwheel hub per AWWA C-500 for a portable air motor to drive the gear system and a local mechanical position indicator. Handwheel may be disassembled after factory tests for shipping convenience. Flat-face gaskets shall be provided by manufacturer for all valve flange surfaces. Fastening hardware and thread lubricant of non-petroleum base type shall be provided by Contractor for attachment of each valve to the adjacent interface surfaces. Extra-long bolts shall be supplied to accommodate the fastening of the butterfly valve to fiberglass flange of various thicknesses as specified by the Contractor and approved by MARAFIQ.

2.3 A.

B.

2.

3.

4.

2.4 A.

MOTOR OPERATORS Motor operators furnished with the driven equipment shall have total enclosed weatherproof enclosures per NEMA-4x.

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B.

The motor for each valve shall be capable of opening and closing against the design head and the design flow specified herein by an open, close, and stop pushbutton. Valve operation time from full open to full close position shall be 120 seconds minimum. A means shall be provided to disengage the motor drive when the valve is operated manually. The handwheel shall be automatically disengaged when the valve is motor operated. It shall be impossible to place the unit in manual operation while the motor operator is energized. The motor operator shall be provided with double-acting torque switches capable of limiting the applied load in both the open and closed positions as well as protecting the valve parts from overload over the complete stem travel. The motor operator shall be provided with adjustable limit switches capable of providing the functions out-lined in Table 1A, Table of Limit Switch Contact Development, with local controls, future remote control and a minimum of two (2) spare contacts. The motor operator shall be provided with a space heater in the limit switch compartment. Heater shall be rated at 230V and operated at 120V single phase at 60 Hz. A drain plug will be provided for limit switch compartment of valve motor operators. A visual indicator to show the valve position (open/close indication) shall be located on the operator and shall be directly linked mechanically with the shaft of the valve. All motors shall be provided with integral motor starters and controls. Table 1-A shows limit switch contact development. TABLE 1A TABLE OF LIMIT SWITCH CONTACT DEVELOPMENT Valve Full Open Closed Closed Open Open Open Open Closed Closed Closed Closed Open Open Open Open Intermediate Valve Position Open Open Closed Closed Open Open Closed Closed Open Open Closed Closed Open Open Valve Full Closed Open Open Closed Closed Closed Closed Open Open Open Open Closed Closed Closed Closed

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H. I.

Contact 1 2 3 4 5 6 7 8 9 10 11 12 13 14

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15 16 J. K.

Closed Closed

Closed Closed

Open Open

All auxiliary contacts shall be wired to terminal blocks. Motor operators shall be provided with terminal block connections for remote operation and monitoring.

2.5 A.

EXPANSION JOINTS All expansion joints shall be designed to withstand 51 m water pressure, 5.0 m vacuum, 42oC temperature, and seawater conditions shown in Table 1. The outside surfaces will be fully or partially submerged in seawater. The expansion joints shall be supplied with flanges constructed and drilled in accordance with ANSI B16.1, Class 125 for sizes up to 2400 mm and AWWA C 207 Class D for all larger sizes. Flange material shall be ASTM B 169 CA 614 and Al-Bronze B148 CA 958 in accordance with paragraph 2.2.A and notes 1 and 2 of paragraph 2.2.B of this specification. The joint shall be constructed of molded rubber with fabric reinforcement. The joint shall be shaped to provide a continuous belt rubber expansion element. Surfaces of all bored holes in rubber material shall be sealed. Rods and other restraints shall be provided as part of expansion joint to protect the flexible element from excessive displacement. The restraints shall permit a 25.4mm axial compression, 14.3-mm elongation, and 12.7-mm lateral movement. All hardware for attachment of expansion joint to adjacent flanges including flange backup rings, nuts, bolts, isolation ferrules, washers, and thread lubricant shall be supplied. Extra long bolts shall be provided to allow the fastening of expansion joints to various thickness of fiberglass flanges as specified by the Contractor and approved by MARAFIQ. The attachment hardware shall not contribute to or be subjected to corrosion from seawater or galvanic attack. The rubber expansion joint shall be given a protective coating for protection against accidental contact with oil. Suitable cover shall be provided to envelop the rubber expansion joints as protection against solar radiation.

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G.

PART 3 3.1 A.

EXECUTION

VALVES AND EXPANSION JOINT INSTALLATION Generally, installation of valves and expansion joint shall be done after installation of the GRP pipes and shall be in accordance with the manufacturer's written instructions.

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B.

Connection of Butterfly Valves and Expansion Joints: 1. Screw the stud bolts on the expansion joint side flange of the butterfly valve and then attach the butterfly valve. Tighten the flange bolts uniformly and tightly. Bolt torque limitations shall be in accordance with the valve and pipe manufacturer's given and written instructions.

2.

C.

Installation of Butterfly Valve and Expansion Joints: 1. Compress the expansion joints by tightening the nut on the long bolts of expansion joint. Place the butterfly valve and expansion joint assembly between the GRP pipe flanges. Loosen the nut for long bolts of expansion joints and set the nuts in place. Set the flange anchor bolts for the flange connection of the butterfly valve. Tighten the flange bolts, nuts and nuts for flange anchor bolts tightly and uniformly.

2.

3. 4. 5.

D.

Finally, place the concrete for the flange anchor bolt. For removal of the butterfly valve and expansion joint, remove the concrete and follow above steps reversibly. Generally, installation of slow closing air and vacuum valves should be done after installation of the GRP pipes and shall be in accordance with the manufacturer's written instructions. Since all flange materials will be aluminum-bronze, isolation ferrules will be provided for bolt holes to avoid contact of the al-bronze bolts with the cast or steel surface. Hence, isolation ferrules are not required for connections with al-bronze and fiberglass materials. Connection of Slow Closing Air and Vacuum Valves: Tighten the flange bolts uniformly and tightly. Bolt torque limitations shall be in accordance with the valve and pipe manufacturer's written instructions. Installation of Slow Closing Air and Vacuum Valves and Miscellaneous Valves: 1. Place the slow closing air and vacuum valves assembly on the GRP pipe flanges. An isolation butterfly valve shall be placed between the seawater pipe flange and air and vacuum valve. Set the nuts in place as shown in the drawings. Tighten the flange bolts and nuts tightly and uniformly.

E.

F.

G.

2. 3. H.

Generally, installation of valves should be done in accordance with the manufacturer's written instructions. Isolation ferrules will be provided for bolt holes

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to avoid contact with the different hardware surfaces. Hence, isolation ferrules are not required for connections with hardware steel and non-hardware steel materials (e.g. FRP, RTRP, etc.). I. Connection of Valves: Tighten the flange bolts uniformly and tightly. Bolt torque limitations shall be in accordance with the valve and pipe manufacturer's given and written instructions. MATERIAL PREPARATION AND SHOP PAINTING Surface Preparation: Bronze materials shall not be painted. Exposed steel surfaces shall be painted in accordance with standards, SSPC-PS-11.00 coal tar epoxy or SSPC-PS-13.00 epoxy equivalent. The application service conditions for this specification is classified as "submerged surfaces, SSPC Zone 2.B." Surface preparation shall be by sand blasting in accordance with SSPC-SP5. Prime and Intermediate Coating: 1. Prime and intermediate coatings shall be modified alicylic polyamine-cured, high build, epoxy primer at 100 microns thickness each coat or a total of 200 microns.

3.2 A.

B.

C.

Finish Coating: Finish coating shall be modified alicylic polyamine-cured, high build, epoxy coating with a minimum dry film thickness of 100 microns. TAGGING OF EUQIPMENT Identification numbers will be assigned by the MARAFIQ to all valves. Corrosionresistant tags with these numbers shall be permanently attached to the valves. Each valve shall either have the inlet connection designated or the direction of flow shown. Each valve and expansion joint shall be fitted with corrosion resistant nameplates that identify the equipment. The nameplates shall be in Arabic and English language. 1. The limit switch contacts listed in the Table 1A shall be rated to interrupt no less than 0.5 ampere resistive load at 125 volts dc and 15 ampere inductive load at 120 volts, 60 Hertz. Limit switches shall be installed in a manner that will not interfere with the normal operation of the valve. The range of adjustment shall be up to onehalf of the valve stroke. Limit and torque switches shall be rigidly mounted to preclude misalignment when the Purchaser's conduit is connected to the switch enclosure. Switch enclosures shall be NEMA Type 4X.

3.3 A.

B.

C.

2.

3.

4. 3.4

INSPECTION

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A.

Quality control inspection and acceptance shall be in accordance with the requirements of Section 01420 of the Contract documents.

+ + END OF SECTION 15103 + +

P.O. Number : 7200018725