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NAME OF WORK:

CONSTRUCTION OF SEWERAGE SYSTEM FOR SEWERAGE DISTRICT - III OF BHUBANESWAR CITY

2.12

Valves

2.12.1 General

Valves shall be suitable for use with the fluid being conveyed at the temperatures and pressures required for the application. Generally, pressure designation shall not be less than PN 1.0.valves shall have integral flanges drilled as specified in relevant latest IS specifications or BS: 4504. Flanges to other standards shall be used only if approved and provided that any differences do not affect mating dimensions. Back faces of flanges shall be machined. Sluice valves and butterfly valves shall be suitable for flow in either direction. Sluice valves shall comply with IS: 14846 or other relevant latest IS specifications, IS: 2685:1971, IS: 2906:1984

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and IS specifications or BS: 5155/ WWA-C 504/1980. Reflux /check valves shall conform to IS: 5312 or BS: 5153.

Valves shall be suitable for frequent operation, and for infrequent operation after long periods of standing either open or closed. Rubber used in valves shall be ethylene propylene rubber (EPDM or EPM) or styrene butadiene rubber (SBR). It shall comply with the requirements of Appendix B of BS: 5155 or of latest I S specifications, be suitable for making a long term flexible seals, and be resistant to anything causing deterioration of the flexible seal. 2.12.2 Eccentric Plug Valve

Eccentric Plug Valves shall be of the tight closing, resilient faced, non-lubricating variety and shall be of eccentric design such that the valves pressure member (plug) rises off the body seat contact area immediately upon shaft rotation during the opening movement. Valves shall be drop-tight at the rated pressure (175 psi through 12", 150 psi 14" and above) and shall be satisfactory for applications involving throttling service as well as frequent or infrequent on-off service. The valve closing member should rotate approximately 90 degrees from the full-open to full-close position and vice-versa. The valve body shall be constructed of cast iron (semi-steel) conforming to ASTM A126, Class B. Body ends shall be:

1. Flanged with dimensions, facing, and drilling in full conformance with A-ANSI B16.1, Class 125. This includes flange thickness. 2. Mechanical joint to meet requirements of AWWA C111/ANSI A21.11. 3. Grooved ends to meet requirements of AWWA C606.

Eccentric plug valves shall have a rectangular or circular shaped port. Port areas for 3” – 20” valves shall be a minimum 80% of full pipe area.

Valve seat surface shall be welded-in overlay, cylindrically shaped of not less that 90% pure nickel. Seat area shall be raised, with raised areas completely covered with weld to insure proper seal contact. The machined seat area shall be a minimum of .125 thick and .500" wide.

The valve plug shall be constructed of cast iron (semi-steel) conforming to ASTM - A126, Class B. The plug shall have cylindrical seating surface that is offset from the center of the plug shafts. The plug shafts shall be integral. The entire plug shall be 100% encapsulated with Buna-N rubber in all valve sizes. The rubber compound shall be approximately 70 (Shore A) durometer hardness. The rubber to metal bond must withstand 75 lbs. pull under test procedure ASTM D - 429 - 73 Method B. Shaft bearings, upper and lower, shall be sleeve type metal bearings, centered; oil impregnated and permanently lubricated type 316 stainless steel conforming to ASTM A743 Grade CF-8M. Thrust bearings shall be Nylatron.

Plug valve shaft seals shall be on the multiple V-ring type (Chevron) and shall be adjustable. All packing shall be replaceable without removing the bonnet or actuator and while the valve is in service. Shaft seals shall be made of Buna-N.

Each valve shall be given a test against the seat at the full rated working pressure and a hydrostatic shell test at twice the rated working pressure. Certified copies of individual tests shall be submitted when requested. Certified copies of proof-of- design tests shall be submitted upon request. Manual valves shall have lever or worm gear type actuators with hand wheels, 2" square nuts, or chain wheels attached. Lever actuators shall be furnished on valves 8" and smaller where the maximum unseating pressure is 25 psig or less.

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Worm gear type actuators shall be furnished on all 4" or larger valves where the maximum unseating pressure is 25 psig or more.

100% port eccentric plug valves shall be designed and/or tested to meet the following standards:

1. AWWA C517-05 Resilient-Seated Cast-Iron Eccentric Plug Valve.

2. ANSI flange drilling conforms to ANSI B16.1, Class 125 and ANSI B16.5, Class 150.

3. Mechanical-joint end connections conform to ANSI/AWWA C111/A21.11.

4. MSS-SP91 guidelines for manual operation of valves.

5. Metric 10 bar flange drilling conform to the NP 10 requirements ISO 2084, to the 10 bar requirements of BS: 4504

6. Metric 16 bar flange drilling conform to the NP 16 requirements of ISO 2084, to the 16 bar requirements of BS: 4504

7. British Table D flange drilling and Table E flange drilling conform to BS:

10.

2.12.3 Gate Valves (Sluice Valves)

The design, manufacture and construction features of sluice valves shall comply with IS 14846 or equivalent international standards. The valve shall be suitable for installation with the valves or spindle in any position. Valve flange shall be parallel to each other and flange face shall be right angle to valves center line. Backside of the valves flanges shall be machined or spot faced for proper seating of bolt head and nut. Sluice valves shall be double flanged rising stem type. The valves shall be provided with hand wheel. The valves shall be closed with clockwise rotation of the hand wheel. The direction of closing and opening shall be marked on the hand wheel. Valves of 350mm & above shall be provided with renewable shoe channel arrangement so that gate shall be guided throughout its travel. Valves up to 300mm shall be provided with manual wheel arrangement. Valves above 300mm & up to 500mm shall be provided with manual enclosed gear arrangement and above 600mm size shall be provided with electric actuator arrangement. All the valves shall be subjected to hydraulic test as per relevant code.

Martial of construction:

1. Body and wedge

-

CI as per IS 210 Gr FG-260

-

2. Spindle 19 Ni 9)

Stain less steel IS: 6603(04cr

3. Spindle nut

-

Bronze IS: 318 LTB-2

4. Body and seat ring

-

SS-316/CF-8M

5. Shoe and channel lining

-

SS-304

6. Fasteners

-

SS-304.

7. Bearing

-

SKG/FAG.

2.12.4 Non-return (Check) Valves

Non return Valve shall be of swing or Ball type. Swing Type Non Return Valve:- The design, manufacture & construction features of Non- return valves comply with IS 5312 I for single door type & IS-5312 II for multi door type or equivalent international standards. Non-return swing check valves shall be designed for rapid closing without slamming no later than the moment forward flow stops. The valve design shall be chosen to give the best performance possible. Taking in to

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account of the system where valve is installed, the effect of any surge in the system as well as static & dynamic heads shall be included in the assessment. If self-closing without slamming cannot be achieved, external mechanism may be used to control the closure rate. Details of mechanism will be subjected to approval. Non return valve used in sludge system shall not be installed vertically positioned so that solids can settle against the valve flap when flap is closed. Direction of flow shall be clearly embossed on the valve body. Valves of size

600m & above shall be of multi door type. The materials of construction of different parts of swing type check valve shall be as follows.

1. Body & door

-

Cl conforming to IS 210 Gr FG260

-

2. Body rings

-

conforming to SS-316.

3. Door rings

-

conforming to SS-316.

4. Bearing bushes

Leaded tin bronze IS 318GrLTB-2.

5. Ball (if applicable)

-

To be covered with EPDM rubber.

6. Bolt & nuts

-

SS-304.

Test: The necessary tests shall be carried out as relevant code.

2.12.5 Butterfly Valves

All butterfly valves shall be of PN-1 rating manually operated having double- flanged sturdy valve body with face-to-face length & flange drilled (IS 1538) generally conforming to IS13095 requirement. The material of construction of various components shall be suitable for handling sewage.

Body, Disc and Disc Cover

Cast Iron- IS210 –Grade- FG 300 SG Iron SG 400/12 IS:1865

Disc Seal

EPDM rubber

Body Seat ring

Stainless steel- ASTM A-276, Grade AISI: 316

Split thrust ring

Bronze IS:318 LTB-2

Flanged bush bearing Stub shaft NDE

Bronze IS :318 LTB-2 Stainless Steel: 316

sleeve

SS-410

Dowel Pin

Stainless Steel: 316

Drive Shaft

Stainless Steel: 316

Gasket

CAF IS: 2712

O ring

Nitrile rubber

Fasteners

SS-304

Bearings

Gunmetal, BS1400, Grade: LG2

Seat leakage test: All valves shall be tested for leakage through the seat at 1.5 times the rated pressure. Hydrostatic body test: All valves are tested at 1.5 times the rated pressure for verifying the strength of the body and check for porosity in castings. Disc strength test at body test pressure. All valves shall have mechanical indicator arrangement for disc position indication and mechanical stops to limit over travel of disc. All valves shall be checked for correct mechanical operation, dimensions and finish.

2.12.6 Pressure-Relief Valves (PRV)

Pressure relief valves shall be designed to prevent the pressure in the pipeline upstream of the valve rising above present level. The valve shall remain closed at lower pressures. The pressure at which the valve opens shall be adjustable. A

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pressure gauge shall be provided to indicate upstream pressure over the operating range of the valve. Safety valves shall comply with BS: 6759: part 1.

They shall be designed to open at the specified pressure and re-close and prevent further release of fluid after normal pressure has been restored. The pressure/temperature rating shall be in accordance with table PE-1 in BS: 1560:

Part 2. Shell materials shall be from the materials listed in table PE-1 BS: 1560:

part 2. Flanged ends shall be class 900, raised face type complying with ANSI B16.25 or Table PE-1 of BS: 1560. Butt-welded ends shall be in accordance with Section 8 of BS: 1868.

2.12.7 Ball Valves

Ball valves shall conform where applicable to BS:5159. Multi piece bodies shall be used where work on the ball and seats when installed may be needed. If valves need removal for servicing, one-piece bodies may be used. Seat materials shall be chosen for long life, with erosion and corrosion resistance. Ball supports shall be of the floating ball or trunnion type. If line pressure is too low to ensure a positive leak-free seal, built-in seat loading devices, or specially shaped seating’s shall be used to ensure sealing.

2.12.8 Knife Gate Valves

The valve shall meet requirements of MSS SP 81 Outer body shall be provided with inner liner in corrosion resistant stainless steel which shall extend in to the gland. The body shall be devoid of any wedge/dead pockets to avoid setting of suspended particles and solid in the service fluid. The gate /plate shall be precision buffed and the edge contoured to a knife edge. The gate move along /is guided by the seat ring to ensure that it scraps any deposit/scale enabling smooth uninterrupted movement. Seat shall be so designed that there is no recess /relieve groove to harbor deposition that could build up and swamp the valve. The design shall also in-corporate bosses that guide the gate and avoid deflection ensuring positive shut off. The stem shall have double start threads cut in order to ensure smooth and speedy operation. Gland packing shall offer minimum frictional resistance. As positive sealing element; the packing shall also include a resilient rubber ring. The knife edge and seat face in flow path shall be hard faced to a hardness of 400 to 450 BHN to counter erosion. In such cases, provision shall be made to ensure the fluid contact with seat ring is minimal.

The material of construction of valve shall be as follows.

Component

Material

y

IS .210 Gr FG-260/DI

lining e gate /plate

.

BS.970 Gr 316

.

BS.970 Gr 316.

 

.

BS.970 Gr 316

ing/Boss

.

BS.970 Gr 316

d

housing

.IS-210 Gr FG260

d

housing

on impregnated with asbestos rubber

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2.12.9 Fire Hydrant Valve

Supply, delivery and fixing brand new underground CI Fire Hydrant (sluice type) valve conforming to IS:909-1992 with 63.5 mm Instantaneous pattern single outlet fitted with bolts and nuts, CI loose cap fitted with wrought iron chain, tested to a pressure of 10 Kg/Cm2 and providing, fixing and jointing true to line, alignment and gradient suitable dia. CI double flanged sluice valve (IS:14846), DI D/F pipe, tail pieces, duck foot bend, connecting sleeves as per relevant IS.

The Fire hydrant valve shall be along with surface box. The material of construction of various components shall be as follows:

Valve Body /Bonnet

:Cast Iron- IS210 –Grade- FG 200

Valve

:GM IS-318

Valve seat

:GM IS-318

Spindle

: Brass IS :319

Spindle Nut

:

: GM IS-318

Retainer/ clamping ring

: MS 2062 GR .F e 410

Chain

: Galvanized MS

Spindle Cap/ Cap

: C.I IS-210

outlet

: GM IS-318

Gland

: C.I IS-210

Fasteners

: G.I IS 1367/SS

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2.14 Valve Operation

Shafts and caps for tee-key operated valves. Operating and extension shafts for valves operated by the tee key shall be caped. Extensions shafts shall be circular section. For valves installed in chambers, extension shafts shall be provided with split bearings, rigidly held on brackets spaced not more than 1500mm apart. For buried valves, the shaft shall be supported inside a protecting tube held on a purpose made support, which shall be fixed to top of the valve and provided with a shaft guide. Bearings and shafts shall be suitably protected against corrosion. Extension shaft couplings shall be provided with locking arrangements.

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2.15

Manual Operating Mechanisms

Manual closing of valves shall be by the clockwise rotation of a tee key or hand wheel. Tee-key operated valves shall be provided with detachable cast iron shaft caps, with keys to match the cap. One key shall be supplied for every five valves installed, with a minimum requirement of two keys in any one size. Hand wheels shall be shaped to give a safe grip without sharp projections clearly marked with the direction of opening and closing and shall be fitted with integral locking devices. A padlock and chain will not be acceptable for locking. Manually operated valves and penstock shall be capable of being opened and closed by one person, when the specified max. Unbalanced pressure id applied to the valve or penstock. Under this condition the total force required at the rim of the hand wheel or at the tee key to open the valve or penstock from the closed position shall not exceed 30 kg (15 kg each hand).

Where necessary, gearing and bearings shall be provided and the hand wheel sized to fulfill this requirement. Gearboxes shall be totally enclosed oil bath lubricated. Thrust bearings shall be provided so that the gear case may be opened for inspection or be dismantled without releasing the stem thrust or taking the valve or penstock out of service. Oil and grease lubricated gearing, bearings and glands shall be protected against the ingress of dust and moisture. Operating mechanism shall be of the weatherproof type and those parts subject to submergence shall have a degree of protection IP68 to BS: 5490 at a depth of submergence of 5m. Where practicable, operating mechanisms shall be fitted with mechanical position indicators clearly visible from the operating position. Headstocks of the non rising shaft type shall each have an index pointer working over a graduated, open-to-closed position indicator fixed to the side of the pillar.

2.16 Electric Actuators

Electric actuators shall operate valves and penstocks at opening and closing rates that will not impose unacceptable surge pressures on the pipe work. Actuators shall be rated at not less than 20 percent in excess of the power required to operate the valve or penstock under maximum working conditions. Actuator enclosures shall have a minimum protection IPW 65 to BS: EN 60529. Actuator electric motors shall permit the successive full travel operation of the travel from open to closed and vice versa but shall not be less than 15 minutes. For modulating type actuators the motor shall have a duty-type rating (DTR) to meet the varying cyclic load requirements of the valve. Electric motors shall be provided with built-in thermal protection complying with BS: 4999 Part 111. Actuators shall be complete with:

1. An alternative system for manual hand wheel and reduction gear operation which shall be lockable.

2. An interlock, to prevent engagement of the hand wheel whilst the actuator is being power drive and to disengage the manual drive positively when the power drive is started.

3. Reserving type motor starter complete with isolating switch.

4. Local and remote control selector switch when specified, which shall be lockable.

5. Open, stop and close push-buttons.

6. Potentiometer for remote valve position indication when remote control is specified.

7. Torque switches for mechanical disengagement of the drive at the extremes of valve operation to limit excess torque.

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8.

Supply failure and remote control available monitoring relays. The supply failure relay shall operate under single phasing relays as necessary.

9. Auxiliary and interposing relay as necessary.

10. Voltage-free changeover type contacts for the remote indication of

11. Motor tripped on overload

12. Fully open

13. Fully closed

14. Operating

15. Supply failed

16. Remote control available

The rating of volt-free contacts shall be not less than 15A at 240 V A.C and 2 A at 50 D.C unless otherwise specified. The contacts shall be suitable for inductive load switching. Anti-condensation heater: Separate or segregated terminal boxes shall be provided for the connection motor, heater and control cables.

2.17 Valve Packaging and Installation

The Contractor shall provide all equipment needed to handle and install valves and associated equipment without damage to any coatings. The equipment shall include lifting beams, reinforced canvas slings, protective padding, cradles and the like. Wire rope or chain slings shall not be used for handling these items. Temporary packing, coverings or crates provided for protection in transit shall not be removed (except for inspection purposes after which they shall be replaced) until immediately before installation.

2.17.1 Marking and Packing

Each valve shall be indelibly marked with the diameter pressures rating and shall carry a unique reference number to enable each item to be clearly identified with works fabrication records; works test certificates, delivery notes and the like.

Wherever possible, the identification marks shall be painted on the outside of the item but where there is not enough smooth surface area for the identification marks they shall be put on rust proofed metal tags secured to the item with gal vanished wire or chain (not through flange holes). Valves shall be packed in the ‘closed’ position except that uncrated resilient seat gate valves for transport to tropical areas shall be in the ‘open’ position.

2.17.2 Valve Installation

Valves shall be installed and commissioned in accordance with the manufacturer’s instructions. After installation, valves shall be cleaned, gates, discs, seats and other moving parts closely inspected, foreign matter removed, and the valves checked for ease of operation. Moving parts shall be lightly greased or otherwise treated in accordance with the manufacturer’s recommendations.

Unless otherwise specified or directed by the Engineer, butterfly valves shall be enclosed in chambers, installed with the shaft horizontal, and supported as detailed on the drawings. They shall be installed so that when the valve is opening the lower portion of the disc moves in the direction of the main or normal flow. Unless shown otherwise on the drawings, gates valves shall be installed with their shafts vertical.

Gate valves without external gearing, and not otherwise required to be in a

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chamber, may be buried. The buried part of the valve shall be protected as specified. Unless otherwise specified, backfilling shall be to just below the top of the valve or shaft shroud, and a surface box shall be provided. Jointing, sleeving, external wrapping, anchor and thrust blocks, valve chambers, valve marker posts and the cleaning and disinfections of valves shall be executed as specified for the associated pipeline.

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