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   PART 1 - GENERAL

    01 SECTION INCLUDES

    A. Valves and sluice gates for process applications.

    02 REFERENCES

    A. ANSI/AWWA C500 - Standard for Gate Valves for Water and Sewerage Service

    B. ANSI/AWWA C501 - Standard for Cast-Iron Sluice Gates

    C. ASTM A126 - Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings

    D. ASTM A743 - Specification for Castings, Iron-Chromium, Iron-Chromium-Nickel, and Nickel-Base Corrosion-Resistant for General Application

    E. Section 09900 - Painting.

    F. Section 15060 - Pipe and Fittings.

    1.02 SUBMITTALS

    A. Submit the following in accordance with Section 01340.

    B. Schedule of all gates and valves indicating the service, size, connections, make, model number and special features.

    C. Shop drawings to include data sheets for each type and size of gate and valve. Provide separate data sheets for each different type of gate or valve and operator combination.

    D. Manufacturer's written installation instructions.

   PART 2 - PRODUCTS

    03 GENERAL

    A. Marking and identification of valves shall conform to the standard specifications referred to or to the manufacturer's standard.

    B. End connections of valves shall be as shown, but in general valves smaller than 3 inches shall be threaded.

    C. All valves shall open in a counter clockwise direction.

    D. Manual operators for valves 4-inch or larger located with centerlines more than 6-1/2 feet above the operating floor shall have chain or extension operators. Chain wheels shall be malleable cast iron and have chain guides. Chains shall be cadmium plated or stainless steel and shall extend to within five feet of the operating floor. Valves mounted in a vertical position with operator wheel more than six feet above the floor shall be equipped with totally enclosed, permanently lubricated gear operators so that the chain wheel is in a vertical position and extended outward sufficiently so that the chain hangs free.

    E. Valves for non-metallic pipelines shall be of the same material as the pipeline in which installed or lined with, or fabricated from, a material satisfactory for the service intended.

    F. Valve boxes shall be provided for buried valves unless contained in valve basins.

    G. Additional cost required to expedite delivery of valves and/or gates shall be born by the Contractor.

    04 AIR AND VACUUM VALVES

    A. Combination air and vacuum valves for sewage shall permit unrestricted escape of air while pipelines are being drained. When a pipeline is full of liquid the air and vacuum valve shall close watertight when liquid enters the valve. The valve shall allow small pockets of air, which accumulate when the pipeline is operating under pressure, to escape through a small orifice appropriately sized for a working pressure of 250 psi. Valves shall have a ductile iron body, cover and baffle with a stainless steel float. Body inlet shall be baffled to prevent premature valve closure during operation, protect the float from direct air flow, and retain the seats in place without distortion. Valves shall be APCO Series 400 as manufactured by Valve and Primer Corporation, or equal. All valves shall be equipped with back flushing assemblies.

    05 BALL VALVES

    A. Ball valves for use in the chemical feed system for hydrogen sulfide control shall be manufactured of PVC material with teflon seats and viton seals suitable for the temperature and pressure of the systems in which installed. Valve operation shall be manual.

    06 CHECK VALVES

    A. Swing check valves 3-inch and smaller shall have 125-lb. bronze bodies, threaded ends, and removable covers. Valves for oil or gas service shall have composition discs and for other service bronze discs.

    B. Oil controlled swing check valves for shockless service shall have heavy cast iron bodies with bronze or stainless steel seat rings, non-corrosive shafts for weights and levers, and totally enclosed non-corrosive shockless chambers. Seat rings shall be renewable, held in place by stainless steel screws. Valve discs shall be cast iron or steel suspended from non-corrosive shafts extending through stuffing boxes and connected to shockless chambers on the outside of the valves. Discs shall have replaceable rubber seats. Valve flanges shall be ANSI Class 125. Dashpot shall be constructed of steel and provided with two controlling stages in the closing cycle. The new valve shall be supplied with limit switches for activation to indicate pump running status. Manufacturer shall coordinate limit switches with instrumentation supplier. Oil controlled check valves shall be Series 6042B as manufactured by Valve and Primer Corporation (APCO) or approved equal.

    C. Existing oil controlled swing check valves shall be removed and shipped to the manufacturer. The manufacturer shall refurbish the valves to new condition. The manufacturer shall repaint the valves to match new valve. The manufacturer shall provide the same warranty for refurbished valves as new valve. The Contractor shall be responsible for shipping, insurance and storage of the existing valves and shall include this in his lump sum price. The existing valves shall be supplied with new limit switches for activation to confirm pump running status. Manufacturer shall coordinate limit. Switches with instrumentation supplies.

    07 DRAIN VALVES

    A. Drain valves shall be rough bronze sediment faucets with 3/4-inch inlets and 3/4-inch hose thread on outlets.

    08 GATE VALVES

    A. Gate valves 3-inch in size and smaller shall be 125-lb. bronze double wedge disc type with rising stems. Valves shall have union or screwed bonnets and threaded ends and shall be designed for repacking under pressure. The valves shall be furnished with lock shields when indicated.

    B. Gate valves 4-inch and larger in size shall be a solid wedge, tapered wedge type with 200 psi working pressure rating. Valve body shall be constructed of Class B cast iron, stem shall be manganese bronze, bolts shall be electro-zinc plated steel in accordance with ASTM A307, and disc shall be constructed of solid bronze. Valve shall comply with AWWA C500 and shall be Style 2068 by M&H Valve Company, or approved equal.

    C. Existing 42" gate valves shall be removed and shipped to the manufacturer. The manufacturer shall refurbish the valves to new condition. The manufacturer shall repaint the valves to match the new valve. The existing valves shall be provided with a new electric actuators to replace the existing manual actuators. The actuators shall be 480V, 3 phase and sized by the valve manufacturer. The manufacturer shall provide the same warranty for the refurbished valves as the new valves. The Contractor shall be responsible for shipping, insurance, and storage of the existing valves and shall include this in his lump sum price.

    D. The new 42" gate valve shall be electrically actuated. Actuators shall be 480V, 3 phase and sized by the valve manufacturer.

    09 ANGLE SURGE RELIEF VALVES

    A. Surge relief valves suitable for sewage service shall be designed to protect a piping system from surges by opening quickly at a designated pressure and to throttle the flow to maintain the line pressure at no more than 5 to 10 percent above the pressure setting.

    The valve shall be a pneumatic spring cylinder type with spring loaded teflon seals and leakproof construction. The relief pressure shall be adjustable, by changing the air pressure on the pneumatic cylinder. Valve bodies shall be cast iron with renewable aluminum bronze seat rings. Valve seats shall be renewable and resilient. Valve shall be furnished with a pressure gauge with a range four times the relief pressure setting, a soft seated check valve, and a hand valve. Pressure setting shall be ten percent above normal line pressure in the system.

    B. Surge relief valve shall be APCO Series 3000 as manufactured by Valve and Primer Corp., or approved equal.

    C. Existing 16" surge relief valves shall be removed and shipped to the valve manufacturer. The manufacturer shall refurbish the valves to new condition. The manufacturer shall repaint the valves to match the new valves. The manufacturer shall provide the same warranty for the refurbished valves as the new valves. The Contractor shall be responsible for shipping, insurance, and storage of the existing valves and shall include this in his lump sum price.

    010 PLUG VALVES

    A. All plug valves shall be eccentric plug valves unless otherwise specified.

    B. Valves shall be of the non-lubricated eccentric type with resilient faced plugs and shall be furnished with end connections as shown on the plans.

    C. Valve bodies shall be of ASTM A126 Class B cast iron. Bodies in 4" and larger valves shall be furnished with a 1/8" welded overlay seat of not less than 90% pure nickel. Seat area shall be raised, with raised surface completely covered with weld to insure that the plug face contacts only nickel. Screwed-in seats shall not be acceptable.

    D. Plugs shall be of ASTM A126 Class B cast iron. The plug shall have a cylindrical seating surface eccentrically offset from the center of the plug shaft. The interference between the plug face and body seat, with the plug in the closed position, shall be externally adjustable in the field with the valve in the line under pressure. Plug shall be resilient faced with neoprene or hycar, suitable for use with sewage.

    E. Valves shall have sleeve type metal bearings and shall be of sintered, oil impregnated permanently lubricated Type 316 ASTM A743 Grade CF-8M or AISI Type 317L stainless steel. Non-metallic bearings shall not be acceptable.

    F. Valve shaft seals shall be of the multiple V-ring type and shall be externally adjustable and repackable without removing the bonnet or actuator from the valve under pressure. Valves utilizing O-ring seals or non-adjustable packing shall not be acceptable.

    G. Valve pressure ratings shall be 175 psi through 12" and 150 psi for 14" through 72". Each valve shall be given a hydrostatic and seat test with test results being certified when required by the specifications.

    H. Manual valves shall have lever or gear actuators and tee wrenches, extension stems, floorstands, etc., as indicated on the plans. All valves 6" and larger shall be equipped with gear actuators. All manual actuators shall be rated for the full pressure rating of the valve. All gearing shall be enclosed in a semi-steel housing and be suitable for running in a lubricant with seals provided on all shafts to prevent entry of dirt and water into the actuator. The actuator shaft and the quadrant shall be supported on permanently lubricated bronze bearings. Actuators shall clearly indicate valve position and an adjustable stop shall be provided to set closing torque and to provide seat adjustment to compensate for change in pressure differential or flow direction change. All exposed nuts, bolts and washers shall be zinc plated.

    I. Valves and gear actuators for buried or submerged service shall have seals on all shafts and gaskets on the valve and actuator covers to prevent the entry of water. Actuator mounting brackets for buried or submerged service shall be totally enclosed and shall have gasket seals. All exposed nuts, bolts, springs and washers shall be stainless steel.

    J. 54" plug valves shall be furnished with electric motor actuators. Actuators shall be 480V, 3 phase and sized by the valve manufacturer.

    K. Actuators shall be equipped with an operating nut to allow manual valve operation in case of supply failure.

    L. All valves and actuators shall be as manufactured by DeZURIK or approved equal.

    M. Acceptable Manufacturers:

    1. Keystone

    011 SLUICE GATES

    A. Materials of Construction:

    1. Thimble, Frame, Guides and Slide Cast Iron

    2. Yoke Cast Iron

    3. Bearings Bronze

    4. Wedges, Thrust Nut and Stem Couplings Bronze

    5. Seating Faces and Stem guide Lines Bronze

    6. Stems Stainless Steel

    7. Fasteners Stainless Steel

    B. Frames:

    1. The frame shall be of cast iron of ample section and cast in one piece.

    2. The frame shall be designed for the maximum head of 40' with a minimum safety factor of five (5) with respect to tensile, compressive, and shear strength. All surfaces forming joints or bearings shall be machined.

    C. Slides:

    1. The slide shall be of cast iron, with strengthening ribs where required, and a reinforced section to receive the seating faces.

    2. The slide shall be designed with a minimum safety factor of five with respect to tensile compressive and shear strength.

    3. All mating surfaces of the slide shall be accurately machined on contact surfaces.

    4. A thrust nut pocket shall be provided above the horizontal centerline of the slide reinforced by ribs. The thrust nut pocket shall be drained.

    D. Seating Faces:

    1. Seating faces shall be made of strips of rolled or extruded bronze. They shall be firmly secured in finished grooves in the frame and slide faces as to insure that they remain in place, free of distortion and loosening during the life of the sluice gate.

    E. Seals:

    1. Resilient seals for gates shall be of natural or synthetic rubber. Rubber seals shall be resistant to microbiological attack, copper poisoning and ozone attack.

    2. Seals shall be mounted on the slide or frame and shall be securely held in place with a retainer bar bolted to the frame or slide leaving an unobstructed flush invert.

    F. Guides:

    1. Guides shall be made of cast iron and bolted to the frame or cast integrally with it and shall be machined on all bearing and contact faces.

    2. Guides shall be designed for the maximum head required with a safety factory of five for shear, compression and tension. The guides shall be of such length as to support at least one-half of the vertical height of the slide when in the open position.

    3. Provision shall be made to prevent lateral movement of bolted-on guides. They shall be capable of taking the whole thrust produced by water pressure and wedging action with a safety factor of five. Wedges or wedge facings shall be securely attached to the guides at points where, in the closed position, they will make full contact with the wedging surfaces on the slide.

    G. Thrust Nut:

    1. Each gate shall be provided with a thrust nut for connecting the stem to the slide. It shall be of ample design to take the thrust developed during gate operation under the maximum operating head condition loads with a safety factor of five, in opening and closing direction. The thrust nut and slide shall be constructed to prevent turning of the thrust nut in the pocket in the slide. The thrust nut shall be threaded and keyed or threaded and pinned to the stem.

    H. Wedging Devices:

    1. All sluice gates shall be equipped with adjustable side-wedging devices to provide contact between the slide and frame facings when the gate is in closed position. All faces shall be accurately machined to give maximum contact and wedging action. Wedges shall be fully adjustable and so designed that they will remain in the fixed position after adjustment.

    On all gates larger than 24 inches in size that will be subjected to unseating heads, top and bottom wedging devices shall be provided. If the gates are flush bottom closure gates, they will be provided with top wedges only.

    I. Assembly Bolts, Studs, Nuts and Anchor Bolts:

    1. All assembly bolts, studs, nuts, and anchor bolts shall be of such size and spacing as required to provide for the design forces with a safety factor of five. Bolting on circular flanged-back gates shall mate with 25 lb. or 125 lb. drilling as specified in ANSI B16.1. An adequate number of holes shall be provided in the flange on the back of the gate to prevent leakage under the design heads and to resist the shearing action caused by closing and opening forces.

    J. Wall Thimbles:

    1. Wall thimbles shall be made of cast iron and shall be furnished by the gate manufacturer. The wall thimble shall provide a rigid mounting designed to prevent warping of the gate frame during installation.

    2. The cross section of the thimble shall have the shape of the letter "F" or "E", or of a flange and suitable end for attaching to the connecting pipe. The front, or mounting flange shall be machined and shall be drilled and tapped to the same template used for its particular gate frame. A ring shall be cast on the periphery of the wall thimble to form a water stop and anchor ring in the concrete. The gate shall be attached to the wall thimble with bolts or studs specified herein.

    3. To permit entrapped air to escape as the thimble is being encased in concrete, holes shall be cast or drilled in each entrapment zone formed by the reinforcing ribs or the flange and water stops. The holes shall be 1-1/2 inch in diameter and no more than 2 feet apart.

    K. Stems and Stem Couplings:

    1. Where hydraulic cylinder lifts are used, the stem design force shall not be less than 1.25 times the output thrust of the hydraulic cylinder with a pressure equal to the maximum working pressure of the hydraulic fluid supply.

    2. Where stems are furnished in more than one piece, the different sections shall be joined together by solid couplings. The couplings shall be threaded and keyed or threaded and bolted, and shall be of greater strength than the stem.

    L. Stem Guides:

    1. Bracket and floor mounted stem guides (including both the guide housing and the bracket) shall be so constructed that when properly spaced they will hold the stem in alignment and yet allow it enough play to permit easy operation. The inside diameter of the guide shall not be greater than 1/8 inch larger than the outside diameter of the stem. The guides shall be spaced in accordance with the manufacturer's recommendations for each stem size. The L/r ratio shall not be greater than 200. The guides shall be adjustable with respect to the bracket to provide proper concentric alignment with the stem, and shall be so designed that alignment will be maintained after adjustment. The guides shall be lined and provisions shall be made to hold the lining in place. Brackets shall be attached to the wall by sufficient anchor bolts to prevent twisting or sagging under load.

    M. Painting:

    1. Surfaces shall be cleaned by commercial sandblasting to base metal, dry and free of grease before painting in conformance with the paint manufacturer's instructions. After cleaning, the surfaces shall be primed by application of either one shop coat of zinc chromate or a coal tar coating suitable for use in potable water and applied in conformance with paint manufacturer's instructions. After painted surfaces are dry, the machined or bearing surfaces and the holes, both plain and threaded, shall be coated with a protective grease until installation.

    2. The wall thimble shall have the above treatment except for those surfaces in contact with the concrete.

    3. Finish coats shall be as required under Section 09900 - Painting.

    N. Hydraulic Actuated Gates:

    1. General:

    a) A complete electrical and hydraulic operating system shall be furnished to operate four (4) new 72" x 120" sluice gates, four (4) existing 72" x 60" sluice gates, one (1) existing 48" diameter sluice gate, and one (1) existing 12" x 12" sluice gate. The gate manufacturer shall perform the design, manufacture and testing of the complete hydraulic system. The design shall be performed under the direction and review of a Professional Engineer registered in the State of manufacturer of the operating system. All submitted hydraulic and electrical schematics shall be stamped and signed by the registered Professional Engineer. To ensure proper coordination of all interfacing details, the gates and their operating system shall be manufactured at a single location. The system shall conform to the requirements of the component specifications.

    b) The system shall be a nominal 2000 psi self-contained pressurized hydraulic fluid system capable of simultaneously operating two (2) gates at a speed of 12 inches per minute against the specified operating head requirements.

    c) The system shall be designed to use a premium grade, petroleum based, hydraulic fluid, similar to Shell Tellus-23 or equal.

    d) Means shall be provided to allow manual operation of the gate(s) at reduced speed in the event that there is no electrical power available. These provisions shall include a manually operated pump.

    e) The system shall include dual automatically alternating pumps. The alternating pumps shall be arranged so that in the event of failure of one pump to generate its rated flow and pressure the other pump will automatically start. The two pumps shall not run simultaneously.

    f) All necessary controls, transformers and components shall be provided to cause the gates to perform the desired operations, requiring only a single 480 VAC, 3 phase electrical connection. All controls shall be factory installed in an electrical enclosure mounted on the hydraulic power unit.

    g) The hydraulic system and controls shall be designed for indoor installation in a NEMA 4 location.

    2. Controls:

    a) Control Mode:

    1) Provision shall be made to operate the gates from either the hydraulic power unit control panel or from the main control panel.

    2) A single LOCAL-REMOTE selector switch shall be provided which will determine the point of control of the gates.

    b) Local Operation:

    1) When the LOCAL-REMOTE selector switch is in the LOCAL position, it will be possible to open/close the gate(s) independently using manually activated pushbuttons located at the control panel on the power unit. It shall be possible to open or close the gate with one push of the pushbutton.

    c) Remote Operation:

    1) When the LOCAL-REMOTE selector switch is in the REMOTE position, the gates will open/close by the detection of dry contacts at the main control panel.

    2) Provision shall be made in the hydraulic system control panel to detect the remote dry contact closures and operate the appropriate gate.

    d) Controls:

    1) All controls for the hydraulic system shall be installed inside a NEMA 4 enclosure, mounted directly to the power unit.

    2) All controls shall be performed via a programmable controller, similar to Texas Instruments Series 305, or equal.

    3) All programmable controller software shall be fully documented.

    4) All necessary motor starters and motor circuit protectors shall be installed inside the control enclosure.

    5) The control enclosure shall be provided with a fused disconnect switch.

    e) Position Indication:

    1) Limit travel indication for all gates shall be provided via limit switches supplied integrally mounted to the cylinders. Limit travel shall be displayed using indicating lights on the control panel, mounted on the power unit and at the main control panel. Limit switches shall be explosion proof; rated for Class I, Division I environment.

    f) Interconnecting Piping:

    1) Seamless or welded stainless steel hydraulic piping shall be installed between the hydraulic power unit and the hydraulic cylinder(s).

    This interconnecting piping shall be of a minimum size as recommended by the gate manufacturer.

    2) All interconnecting piping shall have socket welded fittings.

    3) All piping, pipe fittings, cored holes or drilled holes shall be free of burrs or foreign matter that might cause damage to any hydraulic component or contamination of the hydraulic fluid before installation.

    4) After fit-up, all interconnecting piping shall be thoroughly flushed, to remove all dirt and debris, before connection to the hydraulic cylinder or hydraulic power unit.

    5) High pressure hose, suitable for 2000 psi and compatible with the hydraulic fluid used in the system. The hose shall be provided by the Contractor to connect between the interconnecting piping and both the hydraulic cylinder and hydraulic power unit. The hose will allow flexibility during installation and service, as well as reducing vibration and shock.

    6) At the power unit end, field installed piping shall be terminated with a flexible hose connecting to the hydraulic power unit ball valves. At the cylinder end, field installed piping shall include a full ported, stainless steel, pressure rated ball valve and a flexible hose connecting the ball valve to the hydraulic port of the cylinder.

    7) The Contractor shall supply and install air bleed valves at all high points in the field piping.

    8) The Contractor shall field route and support the piping as recommended by the pipe manufacturer and approved by the Engineer.

    O. The Contractor shall supply a complete and operating sluice gate system with all required accessories. The sluice gates shall be sized as shown on the Sluice Gate Schedule shown on the drawings.

    P. The sluice gate system shall be as manufactured by Rodney Hunt Company, Orange, Mass.

    Q. The complete system shall be handled, stored and installed as recommended by the manufacturer.

    R. A field leakage test shall be performed by the Contractor with the manufacturer's representative present. Under the design head conditions the leakage shall not exceed 0.1 gpm per foot of seating perimeter.

    S. Acceptable Manufacturers:

    1. Rodney Hunt

    2. Waterman

    3. Hydro-Gate

    012 VALVE BOXES

    A. Valve boxes shall be cast iron sectional type. The lower section shall have a minimum diameter of five inches, enlarged to fit around the bonnet of the valve if a 2-section box is used, or to fit a circular or oval base section if a 3-section box is used. The upper section shall slide or screw down over the adjoining lower section and shall be full diameter throughout. Valve boxes shall have cast iron lids or covers. The boxes shall be long enough to permit the top to be set flush with the established ground surface grade.

    013 BURIED VALVES

    A. Buried valves not in valve basins shall have Type 304 stainless steel extension shafts with 2-inch square nuts at ground level and with indicators to show valve position. Shafts shall be enclosed in valve boxes.

    014 ELECTRIC MOTOR ACTUATORS

    A. Motor operator designed to move valve from full open to full closed when electric power is applied, and hold valve at any intermediate position between full open and full closed without creeping or fluttering.

    B. Housing shall be heavy, cast iron and fully gasketed to operate in high humidity environments.

    C. Heavy-duty motor shall operate from 460 VAC (nominal), 3 phase input source.

    Thermal cut-out switches shall be provided in case of motor overload. Internal heater(s) shall be provided to prevent damage owing to condensation within the motor.

    D. Two internal limit switches shall be preset at factory and furnished for each extremity of valve disc travel. Two additional limit switches shall be furnished for signal or auxiliary control.

    E. Electric actuator systems by Auma, Pittsburgh, Pennsylvania, Positron, Aurora, Illinois, Limitorque, or approved equal.

   PART 3 - EXECUTION

    015 INSTALLATION

    A. Valves shall be installed with the stems positioned in the horizontal or above the centerline of the pipe. Operators shall be positioned so that they do not interfere with pedestrian traffic. In passageways or above platforms the minimum clearance between the floor and the lowest protruding point on the valve or operator shall be 6 ft 8 in. All valves shall be accessible for operation, maintenance or removal. Valves shall be arranged to open counterclockwise by handwheel or lever operation unless otherwise indicated in these specifications. Valve operators which are 7 ft 0 in. or more above the operating floor or platform shall be chain wheel operated. Where necessary for operations as described above, valves shall be bevel or spur gear operated. Plug valve 6 in. and larger shall be gear operated, unless specified otherwise.

    B. Positioners or actuators shall be given special support where they overhang from the valve or where the total valve, actuator and position weight is excessive for the size of pipeline.

    END OF SECTION