AWWA C540-02 Actuadores eléctricos para compuertas

The Authoritative Resource for Safe Drinking WaterSM

ANSI/AWWA C540-02(Revision of ANSI/AWWA C540-93)

AWWA Standard

Effective date: Feb. 1, 2003.First edition approved by AWWA Board of Directors Jan. 26, 1987.This edition approved June 16, 2002.Approved by American National Standards Institute Nov. 19, 2002.

Power-Actuating Devices for Valvesand Slide Gates

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6666 West Quincy AvenueDenver, CO 80235-3098T 800.926.7337www.awwa.org

Copyright © 2003 American Water Works Association, All Rights Reserved.

Approved by American National Standards Institute: May 21, 2002.



ii

AWWA StandardThis document is an American Water Works Association (AWWA) standard. It is not a specification. AWWA standardsdescribe minimum requirements and do not contain all of the engineering and administrative information normallycontained in specifications. The AWWA standards usually contain options that must be evaluated by the user of thestandard. Until each optional feature is specified by the user, the product or service is not fully defined. AWWApublication of a standard does not constitute endorsement of any product or product type, nor does AWWA test, certify,or approve any product. The use of AWWA standards is entirely voluntary. AWWA standards are intended to represent aconsensus of the water supply industry that the product described will provide satisfactory service. When AWWA revisesor withdraws this standard, an official notice of action will be placed on the first page of the classified advertisingsection of Journal AWWA. The action becomes effective on the first day of the month following the month of JournalAWWA publication of the official notice.

American National StandardAn American National Standard implies a consensus of those substantially concerned with its scope and provisions. AnAmerican National Standard is intended as a guide to aid the manufacturer, the consumer, and the general public. Theexistence of an American National Standard does not in any respect preclude anyone, whether that person hasapproved the standard or not, from manufacturing, marketing, purchasing, or using products, processes, or proceduresnot conforming to the standard. American National Standards are subject to periodic review, and users are cautionedto obtain the latest editions. Producers of goods made in conformity with an American National Standard areencouraged to state on their own responsibility in advertising and promotional materials or on tags or labels that thegoods are produced in conformity with particular American National Standards.

CAUTION NOTICE: The American National Standards Institute (ANSI) approval date on the front cover of this standardindicates completion of the ANSI approval process. This American National Standard may be revised or withdrawn atany time. ANSI procedures require that action be taken to reaffirm, revise, or withdraw this standard no later than fiveyears from the date of publication. Purchasers of American National Standards may receive current information on allstandards by calling or writing the American National Standards Institute, 25 W. 43rd St., Fourth Floor, New York, NY10036; (212) 642-4900.

Science and Technology

AWWA unites the drinking water community by developing and distributing authoritative scientific and technologicalknowledge. Through its members, AWWA develops industry standards for products and processes that advance publichealth and safety. AWWA also provides quality improvement programs for water and wastewater utilities.

All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronicor mechanical, including photocopy, recording, or any information or retrieval system, except in the form of briefexcerpts or quotations for review purposes, without the written permission of the publisher.

Copyright © 2003 by American Water Works AssociationPrinted in USA





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Committee Personnel

The AWWA Standards Committee on Power-Actuating Devices for Valves and Sluice Gates,which reviewed and approved this standard, had the following personnel at the time ofapproval:

Fred L. Hinker, ChairAmzad Ali, Vice-Chair

Consumer Members

Amzad Ali, Greater Vancouver Water District, Burnaby, B.C. (AWWA)

M.A. Almai, Kansas City Water Services Department, Kansas City, Mo. (AWWA)

J.W. Benson, Memphis Light Gas & Water, Memphis, Tenn. (AWWA)

T.W. Knowlton, Salem–Beverly Water Supply Board, Beverly, Mass. (NEWWA)

D.M. Reidy, Indianapolis Water Company, Indianapolis, Ind. (AWWA)

Charles Staebler, Louisville Water Company, Louisville, Ky. (AWWA)

D.C. Stone, Denver Water Department, Denver, Colo. (AWWA)

General Interest Members

G.A. Aldworth, Aldworth Engineering Inc., North York, Ont. (AWWA)

B.E. Bosserman, Boyle Engineering Corporation, Mission Viejo, Calif. (AWWA)

C.L. McLain,* Moorhead Public Service, Moorhead, Minn. (AWWA)

F.L. Hinker, Consulting Engineer, Santa Rosa, N.M. (AWWA)

J.P. Musich, Wright–Pierce, Topsham, Maine (NEWWA)

W.H. Peffley, Crawford Murphy & Tilly, Springfield, Ill (AWWA)

G.L. Useldinger, Black & Veatch Corporation, Kansas City, Mo. (AWWA)

J.S. Wailes,* Standards Engineer Liaison, AWWA, Denver, Colo. (AWWA)

*Liaison, nonvoting







iv

Producer Members

Robert Arnold, Rotork Controls Inc., Rochester, N.Y. (MSS)

J.V. Ballun, Val-Matic Valve & Manufacturing Corporation, Elmhurst, Ill. (AWWA)

P.E. Brunelle, Rodney Hunt Company, Orange, Mass. (AWWA)

L.H. Elliot, EIM Controls Inc., Missouri City, Texas (VMA)

G.F. Topinka, Maryknoll Engineering, Glen Ellyn, Ill. (AWWA)





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Contents

All AWWA standards follow the general format indicated subsequently. Some variations from this formatmay be found in a particular standard.

SEC. PAGE SEC. PAGE

Foreword

I Introduction..................................... vii

I.A Background...................................... vii

I.B History............................................. vii

II Special Issues.................................... vii

II.A Discussion........................................ vii

II.B Hydraulic Fluid ............................... vii

III Use of This Standard ...................... viii

III.A Purchaser Options and

Alternatives .................................. viii

III.B Modification to Standard.................. xi

IV Major Revisions ................................ xi

V Comments ....................................... xii

Standard

1 General

1.1 Scope ................................................. 1

1.2 Purpose .............................................. 2

1.3 Application ........................................ 2

2 References.......................................... 2

3 Definitions ........................................ 4

4 Requirements

4.1 Data to Be Provided by Actuator

Manufacturer .................................. 6

4.2 Actuator Sizing .................................. 7

4.3 Electric-Motor Actuators—

General Design ............................... 7

4.4 Cylinder and Vane-type Actuators—

General Design ............................. 12

4.5 Painting and Coatings ..................... 21

5 Verification

5.1 General ............................................ 22

5.2 Proof-of-Design Tests ...................... 22

5.3 Performance Tests............................ 25

5.4 Test Certification............................. 26

5.5 Inspection and Testing .................... 27

6 Delivery

6.1 Marking ........................................... 27

6.2 Packaging, Shipping, and Storage .... 27

6.3 Affidavit of Compliance................... 28

Table

1 Prototype Actuator Test

Cycles Required ............................ 25





This page intentionally blank.





vii

Foreword

This foreword is for information only and is not a part of AWWA C540.

I. Introduction.

I.A. Background. This standard describes power-actuating devices that are

externally mounted on gate, ball, plug, cone, globe, and butterfly valves, and on slide

gates suitable for use in water utilities. This standard does not describe pilot and

control apparatus used to actuate the operating device.

I.B. History. The first edition of this standard, published in 1987, was the

result of 12 years of effort by the AWWA Standards Committee on Power-Actuating

Devices for Valves and Sluice Gates. The committee was formed by AWWA in 1974

and charged with the development of standards on prime movers for valves and sluice

gates, including electric motors and cylinders employing air, water, and oil. The

second edition of this standard was approved by the AWWA Board of Directors on

June 6, 1993, and added quarter-turn actuators. This third edition was approved by

the AWWA Board of Directors on June 16, 2002. It adds vane-type actuators and

digital controls.

II. Special Issues.

II.A. Discussion. At the time this standard was approved, three AWWA

standards reference C540 rather than include separate power-actuator sections. The

three standards are AWWA C560, Standard for Cast-Iron Slide Gates; AWWA C504,

Standard for Rubber-Seated Butterfly Valves; and AWWA C507, Standard for Ball

Valves 6 In. Through 48 In. (150 mm Through 1,200 mm).

AWWA C540 describes only the design and performance of those actuating

devices applied to systems with operating pressures normally encountered in water

utilities. Purchasers of power-actuating devices should carefully review the require-

ments of this standard, evaluate the information to be provided to the manufacturer,

and review the data to be supplied by the manufacturer. Such evaluations are essential

to ensure proper application of the power-actuating device for the intended use.

Specific requirements for controls and accessories and other items not described

in this standard must be included in the purchaser’s specifications.

II.B. Hydraulic fluid. Caution should be used in the selection of a hydraulic

fluid to be used in a cylinder actuator. In the event of a malfunction involving

leakage of fluid into the water supply, it is essential that the hydraulic fluid not





viii

impart any taste or odor or contain any organic or inorganic substance harmful to the

water supply or the consuming public. If potable water is used as the hydraulic fluid,

care must be taken to prevent backflow of this water back into the potable system.

III. Use of This Standard. AWWA has no responsibility for the suitability or

compatibility of the provisions of this standard to any intended application by any

user. Accordingly, each user of this standard is responsible for determining that the

standard’s provisions are suitable for and compatible with that user’s intended

application.

This standard includes certain options that must be selected and specified by the

purchaser to completely describe and obtain the actuator desired. In addition to the

factors in Sec. III.A, General Data, other factors to be considered when sizing an

actuator are described in Sec. 4.2, Actuator Sizing. The following summarizes the

options that must be selected and the data that should be covered by the purchaser

in specifications covering actuators manufactured in accordance with this standard:

III.A. Purchaser options and alternatives. Data to be provided by the purchaser

shall include the following:

1. Valve and slide gate characteristics.

a. Size and type of valve or slide gate to be driven by the actuator.

b. Stem or shaft diameter at point of attachment.

c. Rising stem, nonrising stem, or quarter turn.

d. Pitch, lead, hand of thread, or keyway dimensions.

e. Direction of rotation of actuator handwheel to open valve or slide gate

if other than counterclockwise (Sec. 4.3.6).

f. Number of starts and stops per hour for modulating service (Sec. 4.3.7).

g. Requirement for stem protector (Sec. 4.3.13).

h. Weight of gate and stem for slide gate.

i. Seating and unseating torque in foot-pounds (newton-meters), maxi-

mum dynamic torque in foot-pounds (newton-meters) and, when applicable,

thrust in pounds (newtons).

j. Maximum torque and thrust capability of the valve or slide gate.

2. Operating requirements.

a. Type of service.

1) Open–close. Give frequency of operation and travel time duty cycle.

2) Throttling and Modulating. Give operating conditions, input signal to

actuator, and starts per hour.





ix

Class 1—60 starts per hour, maximum



Class 4—1,200 starts per hour, maximum

b. Operating-cycle requirements. Travel time or speed, in seconds or

inches per minute (centimeters per minute), from fully open to fully closed

positions, or the reverse under all operating conditions. State plus and minus

limits (Sec. 4.2.1.2).

c. Maximum unbalanced heads or differential pressures against which the

valve or gate must open or close, and maximum pipeline pressure (Sec. 4.2.1.2).

d. Ambient temperature and humidity ranges.

e. Installation location: outdoors, indoors in a pit, in a vault, or in any

hazardous location if applicable, as defined by the National Electrical Code. If

submergence is expected, give depth and length of time of submergence.

3. Mounting and options.

a. Actuator orientation in relation to valve or slide gate.

b. Type of actuator (Sec. 4.3 or 4.4).

c. Sec. 4.3.1.1, 4.3.1.2, and 4.3.14 describe equipment that is required to

be provided with the electric-motor actuator. The purchaser must describe any

additional materials required for specific applications.

d. Actuator mounting: directly mounted or remotely mounted on a

floorstand and coupled with extension shafting.

e. Special coating system (Sec. 4.5).

f. If an agent of the purchaser is to visit the plant (Sec. 5.5).

g. Special shipping requirements (Sec. 6).

III.A.1. Specific actuator and equipment data. The purchaser shall include the

following supplementary data for specific actuators and driven equipment:

1. Electric-motor actuators.

a. Supply voltage with maximum and minimum variation, phase, and

frequency.

b. NEMA* enclosure design rating, if other than NEMA 4, watertight

(Sec. 4.3.7 and 4.3.10). For special corrosion-resistant applications, contact the

supplier before specifying enclosure type.

* National Electrical Manufacturers Association, 2101 L St. N.W., Washington, DC 20037.







x

c. Number of heaters, their locations, and their supply voltages if

required (Sec. 4.3.10).

d. Position-indication requirement (Sec. 4.3.12) and need for stem

protector (Sec. 4.3.13).

e. Electrical controls: Specify the following features desired and devia-

tions from Sec. 4.3.14.

1. Whether or not the controls are to be integral to the actuator, ped-

estal-mounted, remotely mounted, or supplied by others.

2. If required, extra reversing-starter auxiliary contacts.

3. A standard reversing contactor is controlled through the use of an

integral transformer that provides 120 V. If a transformer is not required,

its deletion and the voltage required must be specified.

4. If the control circuit does not use seal-contacts in push-button

circuits.

5. If push buttons are to be remote mounted, the requirements must

be specified.

6. If indicating lights are required.

7. The number of limit-switch contacts used for interlocking and

position indication in the open, closed, and intermediate positions must

be defined.

f. Process-control signal (Sec. 4.3.14.2).

1. For analog input, indicate signal (e.g., 4-20 ma).

2. For contact closure, indicate voltage and source or dry contact.

3. For digital serial communication, indicate digital communications

protocol (e.g., Device Net, Profibus, Modbus, etc.).

g. Number of feedback and auxiliary devices; if required, function,

wattage, and resistance (Sec. 4.3.14.3).

2. Cylinder and vane actuators.

a. The material references in Sec. 4.4 of AWWA C540 are based on

successful experience. There may be instances where the water is very

aggressive and the listed materials, particularly the bronzes, may not be suitable

for surfaces in components of actuators wetted by the line content. In such

cases, alternative materials, such as low zinc and low aluminum (7 percent

maximum zinc, 2 percent maximum aluminum), should be specified. The





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purchaser should recognize that alternative materials may increase costs and

delay delivery.

b. This standard allows the use of galvanized tie rods (Sec. 4.4.7.8).

Electrogalvanizing is allowed. Users should be aware that electrogalvanizing

offers limited corrosion protection. If corrosion resistance is a concern, then

the user should require stainless-steel rods.

c. Driver medium: air, water, or oil (Sec. 4.4.8).

d. Driver-medium properties if differing from those in Sec. 4.4.8.3,

4.4.8.4, or 4.4.8.5.

e. Minimum and maximum pressure of driver medium when the valve or

slide gate is to be operated (Sec. 4.2.1.2 and 4.4.7.5).

f. If required, adjustable flow-control devices and opening and closing

speeds if other than specified (Sec. 4.4.7.2).

g. Need for special auxiliaries, such as tail, rod fail-safe, or spring-return

actuation, and so forth.

h. Controls and special devices, such as solenoid valves, additional speed-

control valves, manually operated valves, interconnecting piping, limit

switches, and positioners.

i. Material of construction (Sec. 4.4.3, 4.4.4, 4.4.5, and 4.4.6).

j. Pneumatic actuator prelubrication (Sec. 4.4.8.3.1[1] and 4.4.8.3.1[2]).

III.A.2. Data by supplier. On request by the purchaser, the supplier shall

make available the following:

1. Certification of nonmetallic-cylinder-material confirmation tests

(Sec. 4.4.6.9).

2. Certification of proof-of-design test (Sec. 5.2).

3. Certification of performance test (Sec. 5.3).

4. Affidavit of compliance (Sec. 6.3).

5. Drawings and manuals (Sec. 4.1).

III.B. Modification to standard. Any modification to the provisions, defini-

tions, or terminology in this standard must be provided in the purchaser’s

specifications.

IV. Major Revisions. The major revisions to the standard in this edition

include the following:

1. A general provision for quarter-turn vane-type actuators is now included.

2. The duty cycle of an actuator is more completely described.





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3. Digital control interface has been added.

4. Torque switch modifications have been added.

5. The title has been changed to reflect the AWWA nomenclature changing

sluice gate to slide gate.

V. Comments. If you have any comments or questions about this standard,

please contact the AWWA Volunteer and Technical Support Group, FAX (303)

795-7603, or write to the group at 6666 West Quincy Avenue, Denver, CO

80235-3098, or by e-mail at [email protected].





1

AWWA Standard

ANSI/AWWA C540-02(Revision of ANSI/AWWA C540-93)

Power-Actuating Devices for

Valves and Slide Gates

SECTION 1: GENERAL

Sec. 1.1 Scope

This standard describes power-actuating devices for valves 3 in. (75 mm) in

diameter and larger and slide gates in ordinary water service.

1.1.1 Actuator types. Actuators described in this standard are divided into

the following types:

1. Electric-motor type producing a multiturn rotary motion or used to

drive a gearhead drive for a quarter-turn application or electric-motor type with

integral drive for quarter-turn applications, as defined in Sec. 4.3.1.2.

2. Cylinder type producing a linear motion.

3. Quarter-turn cylinder type producing a rotary motion.

4. Quarter-turn vane-type actuator producing a rotary motion.

1.1.2 Actuator function. Actuators shall produce a rotary or linear motion

to activate a valve or slide gate in open–close, throttling, or modulating service.

1.1.3 Excluded actuators. The following types of actuators are not included

in this standard:

1. Motor actuators using water, oil, or gas as the driver medium.





2 AWWA C540-02

1.1.4 Other exclusions. This standard does not include the following:

1. Electric or electronic controls for electric-motor actuators contained

within separate enclosures at a location remote from the actuator or actuator

floorstand.

2. Piping, controls, and positioners for cylinder actuators.

3. Intermediate gearhead or mechanism (nonintegral to actuator) between

electric power-actuator output and valve/gate stem or shaft.

4. The mechanism connecting a cylinder actuator to a valve or slide gate.

Sec. 1.2 Purpose

The purpose of this standard is to define the minimum requirements for power

actuating devices for valves and slide gates, including sizing considerations, design,

verification, delivery, handling, and storage.

Sec. 1.3 Application

This standard can be referenced in specifications for power-actuating devices for

valves and slide gates. The stipulations of this standard apply when this document

has been referenced and then only to power-actuating devices for valves and slide

gates.

SECTION 2: REFERENCES

This standard references the following documents. In their latest editions, they

form a part of this standard to the extent specified within the standard. In any case

of conflict, the requirements of this standard shall prevail.

ANSI*/ASTM† D570—Standard Test Method for Water Absorption of Plastics.

ANSI B93.10—Static Pressure Rating Methods of Square Head Fluid Power

Cylinders.

ANSI B93.29—Fluid Power Systems, Dimensions for Accessories for Cata-

logued Square Head Industrial Fluid Power Cylinders.

*American National Standards Institute, 25 W. 43rd St., Fourth Floor, New York, NY 10036.

†American Society for Testing and Materials, 100 Barr Harbor Dr., West Conshohocken, PA 19428.







POWER-ACTUATING DEVICES 3

ANSI/NEMA* 250—Enclosures for Electrical Equipment (1,000 Volts

Maximum).

ANSI/NEMA MG1—Motors and Generators.

ANSI/NFPA† 70—National Electrical Code.

ASTM A36—Standard Specification for Carbon Structural Steel.

ASTM A48—Standard Specification for Gray Iron Castings.

ASTM A108—Standard Specification for Steel Bars, Carbon, Cold-Finished,

Standard Quality.

ASTM A123—Standard Specification for Zinc (Hot-Dip Galvanized) Coatings

on Iron and Steel Products.

ASTM A126—Standard Specification for Gray Iron Castings for Valves,

Flanges, and Pipe Fittings.

ASTM A153—Standard Specification for Zinc Coating (Hot-Dip) on Iron and

Steel Hardware.

ASTM A216—Standard Specification for Steel Castings, Carbon, Suitable for

Fusion Welding, for High-Temperature Service.

ASTM A276—Standard Specification for Stainless Steel Bars and Shapes.

ASTM A351—Standard Specification for Castings, Austenitic, Austenitic-

Ferritic (Duplex), for Pressure-Containing Parts.

ASTM A395—Standard Specification for Ferritic Ductile Iron Pressure-

Retaining Castings for Use at Elevated Temperatures.

ASTM A436—Standard Specification for Austenitic Gray Iron Castings.

ASTM A439—Standard Specification for Austenitic Ductile Iron Castings.

ASTM A511—Standard Specification for Seamless Stainless Steel Mechanical

Tubing.

ASTM A513—Standard Specification for Electric-Resistance-Welded Carbon

and Alloy Steel Mechanical Tubing.

ASTM A516—Standard Specification for Pressure Vessel Plates, Carbon Steel,

for Moderate- and Lower-Temperature Service.

ASTM A519—Standard Specification for Seamless Carbon and Alloy Steel

Mechanical Tubing.

*National Electrical Manufacturers Association, 2101 L St. N.W., Washington, DC 20037.

†National Fire Protection Association, P.O. Box 9101, One Batterymarch Park, Quincy, MA 02269.





4 AWWA C540-02

ASTM A536—Standard Specification for Ductile Iron Castings.

ASTM A743—Standard Specification for Castings, Iron-Chromium,

Iron-Chromium-Nickel, Corrosion-Resistant, for General Application.

ASTM B85—Standard Specification for Aluminum Alloy Die Castings.

ASTM B117—Standard Practice for Operating Salt Spray (Fog) Apparatus.

ASTM B127—Standard Specification for Nickel-Copper Alloy (UNS 04400)

Plate, Sheet, and Strip.

ASTM B135—Standard Specification for Seamless Brass Tube.

ASTM B154—Standard Test Method for Mercurous Nitrate Test for Copper

and Copper Alloys.

ASTM B164—Standard Specification for Nickel-Copper Alloy Rod, Bar, and

Wire.

ASTM B179—Aluminum Alloys in Ingot and Molten Forms for Castings from

Aluminum Casting Processes.

ASTM B240—Specification for Zinc and Zinc-Aluminum Alloys in Ingot

Form for Foundry and Die Castings.

ASTM B505—Standard Specification for Copper-Base Alloy Continuous

Castings.

CDA* Copper–Brass–Bronze publications.

SECTION 3: DEFINITIONS

The following definitions of terms shall apply in this standard:

1. Actuator: A device or mechanism used to restrain or move a valve

closure member.

2. Actuator manufacturer: The party that manufactures power-actuating

devices.

3. Corrosion-resistant metal: Corrosion-resistant metals shall be stainless

steel, nickel–copper alloy, or bronze, all conforming to the requirements of Sec. 4.4.2.

4. Cylinder actuator: A fluid-powered actuator that uses hydraulic or

pneumatic pressure within a cylinder to restrain or move a closure member.

*Copper Development Association Inc., Box 1840, Greenwich Office Park 2, Greenwich, CT 06836.






5. Duty cycle: The cycle of operation full open to close, or starts per hour,

or reversals per hour that the actuator is required to perform during a defined period

or periods.

6. Electric-motor actuator: A power-actuating device that uses electrical

energy acting through a motor with a gear train to produce a rotary or linear output

motion.

7. Modulate: To move a valve or slide gate to intermediate positions in

response to a variable control signal.

8. Open–close: To move a valve or slide gate to the fully open or fully

closed position in one continuous operation.

9. Power-actuating device: A device that uses electrical energy or hydraulic

or pneumatic pressure to open, close, or position a valve or slide gate.

10. Purchaser: The person, company, or organization that purchases any

materials or work to be performed. The purchaser may be the valve or slide gate

manufacturer, the supplier, or the party that will own and operate the actuator after

installation.

11. Required actuator torque or thrust: The torque or thrust the actuator

must develop to restrain, move, or properly seat a closure member under design

conditions.

12. Supplier: The party that supplies material or services. A supplier may

or may not be the valve or slide gate manufacturer or actuator manufacturer.

13. Tail-rod: An auxiliary rod connected to the piston of a cylinder

actuator that permits an external pull on a valve or slide gate in an emergency

situation.

14. Throttle: To move and maintain a valve or slide gate in an

intermediate position between fully open and fully closed in response to a manually

initiated control.

15. Thrust: A linear force on the stem of a valve or slide gate, generally

expressed in units of pounds (newtons).

16. Torque: A rotary twist or turning moment on the valve stem or shaft

expressed in units of foot-pounds (newton-meters).

17. Valve or slide-gate manufacturer: The party that manufactures valves or

slide gates and also may assemble and test related power-actuating devices and

auxiliaries.





6 AWWA C540-02

SECTION 4: REQUIREMENTS

Sec. 4.1 Data to Be Provided by Actuator Manufacturer

4.1.1 Drawings. When required, the supplier shall submit certified drawings

to the purchaser for review. Drawings shall show the following:

4.1.1.1 Dimensions. Principal dimensions, including those necessary for

interfacing with the valve or slide gate, incoming power, general construction, and

outline of the actuator mechanism.

4.1.1.2 Electric actuators. For electric-motor actuators, the output torque or

thrust, voltage, phases, frequency, nominal power at running torque and locked rotor,

current at running torque and locked rotor, and speed or travel time.

4.1.1.3 Cylinder actuators. For cylinder actuators, the driver medium, pres-

sure rating, bore diameter, rod diameter, and stroke length.

4.1.1.4 Actuator options. The actuator options being supplied.

4.1.1.5 Wiring diagrams. Electrical-wiring diagrams with list of symbols.

4.1.2 Recommended storage practice. This information shall be placed on

the outside of the unit or shipping container as delivered to the job site or to the

purchaser by the supplier.

4.1.3 Installation, operation, and maintenance manuals. When required,

the supplier shall submit manuals containing the following information to the

purchaser:

4.1.3.1 Instructions. Complete installation, operation, and maintenance

instructions.

4.1.3.2 Parts list. Complete parts list.

4.1.3.3 Spare parts. List of recommended spare parts.

4.1.3.4 Special tools. List of special tools for installation, maintenance, or

adjustment.

4.1.3.5 Lubrication guide. Lubrication guide with list of proper lubricants.

4.1.3.6 Certified drawings. One copy of each certified drawing.

4.1.4 Materials. When required, a list of materials used in the actuator shall

be supplied.

4.1.5 Submittal copies. The number of certified drawings, installation

instructions, and operation and maintenance manuals specified by the purchaser shall

be submitted by the supplier.






Sec. 4.2 Actuator Sizing

4.2.1 Actuator sizing considerations.

4.2.1.1 Data. When valves or slide gates are purchased complete with

actuators, the purchaser shall transmit the actuator sizing data, such as required

actuator torque or thrust, shaft diameter, thread characteristics (including right- or

left-hand), and keyway dimensions, to the supplier for actuator sizing.

When an existing valve or slide gate is to be power actuated, the purchaser shall

transmit the sizing data to the supplier.

4.2.1.2 Conditions. The correct determination of torque or thrust depends

on the specification of the most adverse conditions to be encountered at any time

when actuation is necessary. The use of valve pressure ratings or slide gate design

heads without consideration of actual operating conditions may result in oversizing.

4.2.1.2.1 For slide gates, gate valves, knife gate valves, globe valves, and

diaphragm valves, in addition to required actuator torque or thrust (which includes

weight of parts lifted, packing friction, and so forth), it is necessary to know the

following:

1. The maximum torque and thrust running load over the full cycle.

2. For motor actuators, the desired speed of actuation or stroking time.

3. For cylinder actuators, the minimum cylinder pressure at the time of

actuation.

4.2.1.2.2 For butterfly, ball, cone, and plug valves, it is necessary to know the

following:

1. The required actuator torque over the full cycle of operation.

2. For motor actuators, the desired speed of actuation or stroking time.

3. For cylinder actuators, the minimum cylinder pressure at the time of

actuation.

4.2.2 Maximum torque or thrust for multiturn applications (slide gates and

gate valves). The stall torque or maximum thrust output of the actuator shall not

exceed the torque or thrust capability of the valve or slide gate, as determined by the

valve or slide gate manufacturer.

Sec. 4.3 Electric-Motor Actuators—General Design

4.3.1 General.

4.3.1.1 Multiturn applications. The electric-motor actuator for multiturn

applications shall include as one integral unit, but not be limited to, the electric





8 AWWA C540-02

motor, reduction gearing, drive coupling, torque switches, position limit switches,

gear case, and auxiliary handwheel. The valve or slide gate and actuator combination

must be self-locking.

4.3.1.2 Quarter-turn applications. The electric-motor actuator for quarter-

turn applications shall include as one integral unit, but not be limited to, the electric

motor, reduction gearing, drive coupling between the final drive gear and valve stem,

torque switches, position limit switches, gear case, and auxiliary handwheel. The

quarter-turn actuator can be provided in either of the following two styles: (1) a

multiturn actuator directly coupled to an auxiliary final drive gearbox or (2) a

combination of the electric actuator and final drive gear assembly in one housing. In

either case, the valve and actuator combination must be self-locking.

4.3.2 Gears. Reduction shall be accomplished by means of spur, helical,

bevel, or worm gears. Spur, helical, and bevel gears shall be made of steel. Worm

wheel gear teeth shall be made of bronze. The worm shall be hardened steel. The use

of nonmetallic or aluminum gears in the power train is unacceptable.

4.3.3 Lost-motion device. When required by the unseating application, a

lost-motion device independent of gear backlash shall be supplied as an integral part

of the actuator gear train. This device shall allow the motor to attain full speed before

the load is engaged. The lost-motion device shall not be incorporated in actuators

supplied for modulating service.

4.3.4 Bearings. All gears and shafting shall be supported on antifriction

bearings. Where thrust is a consideration, roller or axial-thrust-needle bearings (to

accept thrust) shall be provided.

4.3.5 Lubrication. All gearing and bearings shall be grease- or oil-lubricated.

Seals shall be provided at all shaft penetrations of the gear case to prevent the leakage

of lubricant regardless of position. Lubricants shall be suitable for year-round service

based on prevailing ambient temperature conditions; normal ambient temperature

limits are considered to be 0°F to 150°F (–17.8°C to 65.6°C). The user of this

standard must identify if the application has temperature conditions exceeding these

limits.

4.3.6 Handwheel. The actuator shall be equipped with a handwheel for

manual operation, connected so that operation by the motor shall not cause the

handwheel to rotate, and operation of the handwheel shall not cause the motor to

rotate. If power is returned to the motor while the handwheel is in use, the design of

the unit shall prevent transmission of the motor torque to the handwheel. Use of the








handwheel shall not negate the lost-motion feature (when supplied). The handwheel

shall require a maximum of 80 lb (356 N) on the rim at any point through valve

travel seating or unseating load or of 60 lb (267 N) for running load. The handwheel

shall have an arrow and the word “OPEN” or “CLOSE” indicating the required

direction of rotation. The handwheel shall operate in the clockwise direction to close.

When specified, the external declutch lever shall be able to be padlocked in either the

manual or motor mode.

4.3.7 Motor. Electric motors shall be specifically designed for valve or slide

gate actuator service, as applicable, and shall be totally enclosed and nonventilated.

At a minimum, the electric-motor enclosure shall meet NEMA 4, watertight

construction. When specified, motor enclosure(s) shall be available to meet

NEMA 6, submersible; or NEMA 7, hazardous, requirements. Motors shall be

capable of operating through one complete cycle, open–close–open or close–open–

close, under the maximum specified operating conditions without overheating when

voltage to the motor is within ±10 percent of the specified voltage. Motors shall have

class B insulation at a minimum. Overload protection shall use overload relays or

inherent motor heat sensors embedded in the windings. The purchaser must identify

whether the actuator is to be used for modulating service; open and close service will

be assumed unless modulating service is stated. The purchaser must identify the

operating conditions to be encountered in the application and the type of motor (AC

or DC) to be used.

4.3.8 Limit switches/sensors. Open and close limit switches/sensors shall be

geared to the drive mechanism and in step at all times whether the unit is operated

electrically or manually. The switches/sensors shall be of the field-adjustable type and

capable of being set either fully open, fully closed, or at any intermediate position.

Limit-switch gearing shall be appropriately lubricated and totally enclosed to prevent

the entrance of foreign material or the loss of lubricant.

4.3.9 Torque switches/sensors. The actuator shall include an adjustable

torque-switch/sensor (and thrust-switch/sensor, where applicable) arrangement to

break the control power circuit when a valve requiring torque seating has reached the

fully open or fully closed position (stops), or when an obstruction has been

encountered in either direction of travel. Open and close torque switches/sensors

shall be individually adjustable. An open torque-switch bypass circuit shall be

provided for torque-seated valves or slide gates to eliminate a nuisance trip during





10 AWWA C540-02

unseating. The torque switch shall remove power to the actuator motor within

50 milliseconds of a stalled valve occurrence.

4.3.10 Electrical-controls enclosures. Terminal strips, a space heater (if

required), limit switches, and torque switches shall be housed in compartment(s)

integral to the actuator. At a minimum, the compartment(s) shall meet NEMA 4,

watertight construction. When specified, control compartment(s) shall meet NEMA

6, submersible; or NEMA 7, hazardous, requirements.

4.3.11 Drive coupling. Mating of the electric actuator to driven equipment

shall be accomplished by means of a separate, removable drive coupling (bronze stem

nut for threaded rising stems or steel bushing for shaft and key applications),

permitting installation and removal without disassembly of the actuator. Where an

auxiliary gear box (quarter turn) is supplied as an integral part of the electric actuator,

a separate, removable drive coupling for mating of the actuator to the auxiliary gear

box will not be required. Coupling of the electric actuator to some valve topworks

configurations, such as a rising, rotating, and splined shaft, may be accomplished, if

necessary, without the use of a separate, removable drive coupling.

4.3.12 Position indication. Position indication, when required, shall be

accomplished using an indicator dial or digital display in full step at all times with

valve or slide gate travel during both power or manual operation. The indicator dial

shall be graduated in 25 percent increments at a minimum, that is, closed, quarter

open, half open, three quarters open, and open.

4.3.13 Stem protectors. If required, stem protectors for rising, threaded-stem

applications shall be provided by the supplier in suitable length and diameter to allow

for full extension of the stem. Stem protectors shall couple to the top of the actuator

with a national pipe thread (NPT) or suitable clamping device, and shall be capped

and vented to prevent the entrance of foreign matter and to minimize condensation

inside the cover.

4.3.14 Electrical controls. Actuators can be applied in open-close, throttling

or modulating service. Control can be by contact closure, analog signal or digital

control. Generally, contact closure with seal-in ‘latching’ contacts is used for open–

close service, contact closure without latching contacts is used for throttling service

and an analog signal is used for modulating service. Digital control can be applied to

all three types of service.

Electrical controls, if supplied as integral parts of the actuator electrical

compartment(s) or pedestal mount, shall include but not be limited to reversing






contactor, control power transformer, open–stop–close push buttons and position

indicating light(s) for open–close push buttons, indicating light(s), position feedback

device, local–off–remote selector switch, and solid-state position comparator circuit

for modulating service.

Digitally controlled actuators must always include a local–off–remote selector

switch and an interface board with the motor controls. The interface board shall be

capable of communicating with the DCS, SCADA, or actuator controller/master

station via digital signals, as required.

4.3.14.1 Open–close and throttling service. Controls shall be in accordance

with the following:

4.3.14.1.1 Reversing contactor. Control voltage shall be 120 V, single phase,

60 Hz or 24 VDC. Seal-in latching contacts shall be supplied for use in the push-

button circuits. When specified, additional auxiliary contacts (1 N.O. [normally

open] and 1 N.C. [normally closed]) shall be supplied. The contactor shall be both

electrically and mechanically interlocked. For digital control, seal-in latching contacts

shall be deleted when the selector switch is in the ‘remote’ position.

4.3.14.1.2 Control power transformer. The transformer shall be designed to

transform incoming power to 120-V, single-phase or 24 VDC power. The

transformer shall be complete with fused primary leads and a grounded and fused

secondary.

4.3.14.1.3 Push buttons. Each actuator shall be supplied complete with

open–stop–close push buttons. Push buttons or a selector switch shall be furnished

integral or, when specified, in a separate enclosure for remote mounting. At a

minimum, the remote enclosure shall meet NEMA 4, watertight construction. When

specified, the remote enclosures shall meet NEMA 4X; NEMA 6, submersible; or

NEMA 7, hazardous, requirements.

4.3.14.1.4 Indicating light(s). When specified, each actuator shall be fur-

nished complete with open–close light indication for valve or slide-gate position.

Lenses shall be red for open and green for close. Both lenses shall be lit during

intermediate travel or a separate intermediate light shall be provided. Light(s) shall be

an integral part of the actuator or, when specified, mounted in the separate remote

push-button enclosure.

4.3.14.2 Modulating service. Controls for modulating service shall be as

specified for throttling service plus the following additional requirements:





12 AWWA C540-02

4.3.14.2.1 Reversing contactor. Seal-in latching contacts of the reversing

contactor shall not be supplied for the selector-switch remote position.

4.3.14.2.2 Position feedback device. The feedback device shall be specifi-

cally selected for compatibility with the position-comparator circuit supplied. The

device shall be mechanically driven by gearing from the valve or slide gate stem and

in step at all times whether or not the unit is being operated electrically or manually.

4.3.14.2.3 Selector switch. A local–off–remote, selector-switch function

shall be supplied to isolate the incoming process-signal control function from the

manual push-button controls.

4.3.14.2.4 Position-comparator circuit. The position-comparator circuit

shall be of solid-state, printed-circuit-board design and shall include, but not be

limited to, zero, span, and deadband adjustments. Positioning of the valve or slide

gate should be accomplished by comparing the input from the feedback device with

an incoming process-control signal. The process-control signal shall be 4–20 mA or

as specified by the purchaser.

4.3.14.3 Position transmitter. A position device, independent of the feed-

back device (in the case of modulating service), shall be supplied when a continuous

valve or slide gate position signal is required. It shall be mechanically driven by

gearing from the valve or slide-gate stem and in step at all times whether the unit is

electrically or manually operated.

4.3.14.4 Wiring. All electrical components shall be shop-wired to a terminal

strip(s) to facilitate a minimum of field wiring at the time of installation, including

interwiring of space-heater, limit, and torque switches.

4.3.15 Stop limiting device. All quarter-turn actuators shall be equipped

with independently adjustable stop limiting devices to establish over-travel protection

at both the fully open and fully closed positions. Stops must be externally adjustable

and properly sealed to prevent the entrance of moisture or other contaminants.

Sec. 4.4 Cylinder and Vane-type Actuators—General Design

4.4.1 General. Actuator designs and material selection shall be compatible

with the driver medium and operating pressures to which the actuator will be exposed.

The following three categories of actuator operating pressures and media are described

in this standard: (1) oil-hydraulic actuator operating up to 2,500 psi (17.2 MPa) oil

working pressure, (2) pneumatic actuator operating up to 150 psi (1.03 MPa) air

pressure, and (3) water-hydraulic actuator operating up to 150 psi (1.03 MPa) water






pressure. Water-hydraulic actuator may also be used for hydraulic oil up to 150 psi

(1.03 MPa) provided the seals are compatible with the oil to be used and no adverse

effects will be generated with nonmetallic construction materials.

4.4.2 Materials. All materials designated herein, when used in actuators

produced according to the provisions of this standard, shall conform, at a minimum,

to the requirements designated in Sec. 4.4.2.1 or each material listed. When reference

is made to ANSI, ASTM, or other standards, the latest revision thereof shall apply.

Other materials may be used if specifically accepted by the purchaser.

4.4.2.1 Physical and chemical properties. Materials shall be in conformance

with the physical and chemical requirements of this subsection as follows:

4.4.2.1.1 Cast iron. ASTM A126 class B or ASTM A48 class 40, minimum.

4.4.2.1.2 Ductile iron. ASTM A536 grade 65-45-12 or 60-40-18 or 80-60-

08, or ASTM A395 grade 60-40-18.

4.4.2.1.3 Alloy cast iron. ASTM A436 type 1 or type 2, or ASTM A439

type D2.

4.4.2.1.4 Stainless steel. ASTM A276 type 304 or type 316, or ASTM A743

grade CF8 or CF-8M, or ASTM A351 grade CF8 or grade CF-8M.

4.4.2.1.5 Nickel–copper alloy. ASTM B127 or ASTM B164.

4.4.2.1.6 Carbon steel. ASTM A108.

4.4.2.1.7 Cast steel. ASTM A216 grade WCB.

4.4.2.1.8 Fabricated steel. ASTM A36, ASTM A516, or better.

4.4.2.1.9 Brass or bronze. Components of brass or bronze shall be made to

ASTM standards or the uniform numbering system (UNS) and shall have a

minimum yield strength of 14,000 psi. Any bronze alloy used in the cold-worked

condition shall be capable of passing the mercurous nitrate test in accordance with

ASTM B154 to minimize susceptibility to stress corrosion. Because of dezincification

considerations all bronze parts subject to water contact shall contain not more than

7 percent zinc. All aluminum–bronze parts subject to water contact shall be inhibited

against dealuminization by receiving a temper anneal at 1,200°F (650°C) ±50°F

(28°C) for 1 hr per in. (25.4 mm) of section thickness followed by cooling in moving

air or by water quenching.

4.4.2.1.10 Zinc Alloy. ASTM B-240.

4.4.2.1.11 Aluminum. ASTM B179, Alloy 356.6 (UNS A03561).

4.4.2.1.12 Aluminum. ASTM B85.





14 AWWA C540-02

4.4.3 Oil-hydraulic cylinders. Oil-hydraulic cylinders shall be of tie-rod,

bolted-flange, or welded construction and suitable for operating pressures up to a

maximum of 2,500 psi (17.2 MPa). Minimum burst pressures shall be 10,000 psi

(68.9 MPa).

The purchaser shall select appropriate oil-hydraulic cylinders of tie-rod, bolted-

flange, or welded construction, according to the rated operating oil pressure of the

system designed. Cylinder mounting dimensions shall comply with applicable

requirements of ANSI B93.29 regarding mountings and physical dimensions with

modifications where required to adapt to the valve or slide gate actuator’s cylinder

mounting. Cylinder pressure ratings shall be determined per ANSI B93.10. The

hydraulic cylinders shall be those catalogued by power-cylinder manufacturers

certifying that the selected cylinders comply with the above ANSI standards with

modifications noted. No special corrosion-protection coatings or corrosion-resistant

materials shall be required unless specified by the purchaser. Corrosion-resistant

materials, if required, shall be corrosion-resistant metal or nonmetallic material.

4.4.3.1 Seals. All static and dynamic seals shall be pressure energized and

shall be compatible with the hydraulic fluid to be used.

4.4.3.2 Component suitability. Descriptions of components for oil-hydraulic

cylinders are not listed in detail in Sec. 4.4.4, 4.4.5, or 4.4.6. Purchasers of

oil-hydraulic cylinders may choose to consider materials in Sec. 4.4.2 and provide

specifications on individual components of oil-hydraulic cylinders.

4.4.4 Water-hydraulic cylinders. Water-hydraulic cylinders shall be of tie-rod

or bolted-flange construction and shall have a pressure rating of 150 psi (1.03 MPa)

minimum, as determined by ANSI B93.10. Cylinder mounting dimensions shall

comply with ANSI B93.29 regarding mounting and physical dimensions with

modifications where required to adapt to the valve or slide gate actuator’s cylinder

mounting. Construction materials shall be selected to ensure adequate corrosion

resistance with a design safety factor of 4:1 based on tensile strength.

4.4.4.1 Cylinder barrels. Cylinder barrels shall be bronze, fiberglass-reinforced

plastic, or stainless steel. The inside surface of the barrel shall have a 20-microinch

(0.508-µm) finish or smoother.

4.4.4.2 Heads and caps. Heads and caps shall be bronze, suitable nonmetal-

lic material, ductile iron, or steel. Steel or ductile-iron components shall have all

surfaces plated. The plating shall withstand a salt-spray test of not less than 144 hr in

accordance with ASTM B117.






4.4.4.3 Cylinder pistons. Pistons shall be bronze, suitable nonmetallic mate-

rial, stainless steel, cast iron, ductile iron, or steel. Steel, cast iron, or ductile iron shall

be plated. Plating shall withstand a salt-spray test of not less than 144 hr in

accordance with ASTM B117.

4.4.4.4 Piston rod. Piston rods shall be 30,000-psi (206.8-MPa) minimum

yield strength, stainless-steel hard chrome plated 0.0005-in. (0.0127-mm) thick, and

shall have a 20-microinch (0.508-µm) finish or smoother.

4.4.4.5 Piston-rod bushing. Bushings shall be bronze or nonmetallic materi-

als suitable for water service and having a bearing capacity of 1,500 psi (10.3 MPa)

minimum.

4.4.4.6 Rod seals. Seals shall be nonmetallic elastomeric materials suitable

for water service. Rod seals shall be of a pressure-energized design.

4.4.4.7 Piston seals. Seals shall be nonmetallic elastomeric materials suitable

for water service. Piston seals shall be of a pressure-energized design.

4.4.4.8 Tie rods. Rods shall be carbon steel, cold rolled, with a minimum

yield strength of 60,000 psi (413.7 MPa).

4.4.5 Pneumatic cylinders. Pneumatic cylinders shall be of tie-rod or bolted-

flange construction with a pressure rating of 150 psi (1.03 MPa) minimum. Cylinder

mounting dimensions shall comply with applicable requirements of ANSI B93.15

regarding mountings and physical dimensions with slight modifications where

required to adapt to the valve or slide gate actuator’s cylinder mounting. Cylinder

pressure ratings shall be determined per ANSI B93.10. However, AWWA C540 is

not restricted to such a cylinder category provided the following materials are used

with an adequate design safety factor of 4:1.

4.4.5.1 Cylinder barrels. Barrels shall be bronze, fiberglass-reinforced plastic,

carbon steel, stainless steel, or hard-drawn brass. The inside surface of the barrel shall

have a 20-microinch (0.508-µm) finish or smoother. If carbon-steel material is used,

the inner surface shall be hard chrome plated 0.0005-in. (0.0127-mm) thick or

electroless nickel plated to the same thickness.

4.4.5.2 Heads and caps. Heads and caps shall be carbon steel, suitable

nonmetallic material, or ductile iron. All surfaces, except nonmetallic material, shall

be chrome- or cadmium-plated if specified by the purchaser.

4.4.5.3 Cylinder pistons. Pistons shall be stainless steel, carbon steel, suit-

able nonmetallic material, cast iron, or ductile iron. All carbon-steel, cast-iron, or

ductile-iron surfaces shall be chrome- or cadmium-plated if specified by the





16 AWWA C540-02

purchaser. Metallic pistons shall not be used with nonmetallic cylinder bodies unless

nonmetallic wear strips are provided.

4.4.5.4 Piston rod. Piston rods shall be 30,000 psi (206.8 MPa) minimum-

yield-strength carbon steel or stainless steel. Both materials shall be hard chrome or

electroless nickel plated 0.0005-in. (0.0127-mm) thick and having a 20-microinch

(0.508-µm) finish or smoother.

4.4.5.5 Piston-rod bushing. Piston-rod bushings shall be iron, bronze, or a

nonmetallic material suitable for air service.

4.4.5.6 Rod seals. Rod seals shall be elastomeric materials suitable for air

service and designed to be pressure energized.

4.4.5.7 Piston seals. Piston seals shall be elastomeric materials suitable for air

service. Piston seals shall be of a pressure-energized type.

4.4.5.8 Tie rods. Tie rods shall be carbon steel, cold rolled, with a minimum

yield strength of 60,000 psi (413.7 Mpa).

4.4.6 Nonmetallic water-hydraulic and pneumatic cylinders. Nonmeta l l i c

water-hydraulic and pneumatic cylinders shall be of tie-rod construction and shall

have a pressure rating of 150 psi (1.03 MPa) minimum. Construction materials shall

be selected primarily on the basis of corrosion resistance and also on the basis of

water absorption, creep, and mating-surface compatibility. Such components and

materials selected shall have a minimum safety factor of 4 at the 150-psi (1.03-MPa)

pressure rating. Furthermore, materials selected shall have a maximum water

absorption of 2 percent after 24 hr in a 1/8-in. (3-mm) thick section when tested per

ASTM D570.

4.4.6.1 Cylinder barrels. Cylinder barrels shall be fiberglass-reinforced plas-

tic having an inside surface finish of 20 microinches (0.508-µm) or smoother. No

fiberglass strands shall extend to the inside surface.

4.4.6.2 Heads and caps. Heads and caps shall be molded or machined from

high-modulus thermoplastic, thermoset, or laminated phenolic materials. Fixed-

mounted cylinders shall be attached to the valve or slide gate operating mechanism

using plated or corrosion-protected coated steel plates (as described in Sec. 4.5)

retained to the cylinder proper using tie rods. Pivot-mount cylinders shall be attached

to the valve or slide gate operating mechanism using plated or corrosion-protected

coated clevis or trunnion plates retained to the cylinder proper using tie rods. Such

metallic plates or clevis shall be external to water passages in the cylinder.






4.4.6.3 Cylinder pistons. Cylinder pistons shall be molded or machined

from high-modulus thermoplastic, thermoset, or laminated phenolic materials.

Particular attention shall be paid to ensure that the materials selected do not have

excessive water absorption or lack dimensional stability.

4.4.6.4 Piston rods. Piston rods shall be 30,000 psi (206.8 MPa) minimum

yield strength, stainless-steel, hard chrome plated, 0.0005-in. (0.0127-mm) thick,

having a 20-microinch (0.508-µm) finish or smoother.

4.4.6.5 Piston-rod bushings. Piston-rod bushings shall be bronze or nonme-

tallic materials suitable for water service and having a high bearing capacity of

l,500 psi (10.3 MPa) minimum.

4.4.6.6 Rod seals. Rod seals shall be elastomeric materials suitable for water

service and designed to be pressure energized.

4.4.6.7 Piston seals. Piston seals shall be elastomeric materials suitable for

water service. Piston seals shall be of a pressure-energized design.

4.4.6.8 Tie rods. Tie rods shall be cold-rolled, zinc-plated carbon steel or

stainless steel. Either material shall provide a minimum yield strength of 60,000 psi

(413.7 MPa).

4.4.6.9 Material selection confirmation. Prior to the proof-of-design tests

outlined in Sec. 5.2.3, nonmetallic-material cylinders shall undergo the following

additional tests to demonstrate proper material selection.

4.4.6.9.1 Water absorption effects. Each cylinder to be tested shall be

subjected to 150-psi (1.03-MPa) water pressure at both cylinder ports for a period of

30 days. At the conclusion of the 30 days, the cylinder shall be cycled back and forth

10 times with no more than 7-psi (48-kPa) water pressure being used for the full

cycle.

4.4.6.9.2 Modulus effects. If the same nonmetallic-design cylinders are to be

used for both water-hydraulic and pneumatic service without any changes, the cylinder

shall be tested as a pneumatic unit at 150-psi (1.03-MPa) air pressure for 5 min. No

leakage shall be allowed across the piston in either direction with the piston retained at

midstroke.

4.4.7 Driver media.

4.4.7.1 Scope. This section describes the minimum quality of driver media

to be provided by the purchaser for actuators of the pneumatic, water-hydraulic, and

oil-hydraulic types for valves and slide gates in open–close, throttling, and







18 AWWA C540-02

modulating service. Driver media includes air for pneumatic actuators, water for

water-hydraulic actuators, and oil for oil-hydraulic actuators.

4.4.7.2 Properties described. This standard describes physical, chemical, and

temperature/pressure suitability of the driver medium to actuator components and to

the positioner, where applicable, so as to minimize potential damage to those

components. Physical properties relate to foreign matter, such as scale and dirt, and

to undesirable trace contaminants, such as water vapor and oil mist. Chemical

properties relate to corrosion deterioration caused by aggressive chemicals, low pH

conditions, and excessive dissolved minerals (for example, scaling damage from very

high hardness in water medium). Temperature/pressure properties relate to operating

problems or material damage caused by excessively high or low temperature or

pressure of the medium.

4.4.7.3 Pneumatic-medium requirements.

4.4.7.3.1 Physical.

1. For open–close service. Compressed air shall have dirt and scale

particles and water droplets removed to no larger than 40 µm (1.6 mils). It is

recommended that the purchaser provide air-line lubricators for an open–close

actuator unless otherwise indicated by the actuator manufacturer.

2. For throttling or modulating service (with positioner). Compressed air

shall have dirt and scale particles and water droplets removed to no larger than 5 µm

(0.2 mils). Factory prelubrication of the actuator shall be provided by the actuator

manufacturer unless otherwise specified. It is recommended that the purchaser

provide air-line filters to remove oil-mist droplets to no larger than 5 µm (0.2 mils)

for protection of the positioner. The use of air-line lubricators should be avoided.

3. The purchaser should ensure that water vapor is removed from the

compressed air to a dew-point temperature below that of the lowest ambient

temperature surrounding the actuator and positioner.

4.4.7.3.2 Chemical. Compressed air free of harmful chemicals shall be used

unless otherwise specified. Nonreactive gas (such as nitrogen) may be used in lieu of

compressed air if so specified by the purchaser.

4.4.7.3.3 Temperature/pressure. Compressed-air temperatures up to 130°F

(54.4°C) and pressures up to 150 psi (1.03 MPa) shall be used unless otherwise

specified.

4.4.7.4 Water-hydraulic medium requirements.






4.4.7.4.1 Physical. Hydraulic-water medium shall have dirt and scale parti-

cles removed to no larger than 20 µm (0.8 mils).

4.4.7.4.2 Chemical. Clean water of potable quality having a salinity not

greater than 500 mg/L and a total hardness not greater than 300 mg/L (as CaCO3)

shall be used unless otherwise specified. For potentially aggressive (low-alkaline)

waters, a water analysis that includes total hardness, pH, CO2, and conductivity

should be made and included in the purchaser’s specifications.

4.4.7.4.3 Temperatures/pressure. Hydraulic-water temperatures up to 125°F

(51.6°C) and pressures up to 150 psi (1.03 MPa) shall be used unless otherwise

specified.

4.4.7.5 Oil-hydraulic medium requirements.

4.4.7.5.1 Physical. Hydraulic oil shall have dirt and scale particles and water

droplets removed to no larger than 10 µm. Viscosity of hydraulic oil shall be 135 to

165 SSU (Standard Saybolt Universal) at 100°F (37.8°C) unless otherwise specified.

4.4.7.5.2 Chemical. Hydraulic oil shall be used unless otherwise specified.

Where an alternative oil medium is intended, the purchaser should clearly specify its

characteristics.

4.4.7.5.3 Temperature/pressure. Hydraulic-oil temperatures up to 200°F

(93.3°C) and pressures up to 2,500 psi (17.2 MPa) shall not be exceeded unless

otherwise specified. When hydraulic oil is used with water-hydraulic-type cylinders,

pressures of 150 psi (1.03 MPa) and temperatures of 130°F (54.4°C) shall not be

exceeded.

4.4.8 Quarter-turn cylinder actuators. For operation of quarter-turn valves,

an intermediate mechanism is required to convert a cylinder’s linear output to the

required rotary motion. Acceptable methods of conversion are lever, link/lever, rack

and pinion, and scotch yoke. Pneumatic quarter-turn rotary vane-type actuators need

no intermediate mechanism. Each design has inherent advantages that should be

reviewed by the purchaser.

4.4.8.1 General requirements. The actuator shall include a rigid housing or

structure for mounting to the valve and supporting the cylinder. Housings, supports,

and connections shall be designed with a minimum safety factor of 5, based on the

ultimate strength, or a minimum safety factor of 3, based on the yield strength of

materials used. Linkage shall contain an adjustment for setting the valve in the closed

position.





20 AWWA C540-02

4.4.8.2 Bearings. All moving surfaces shall be supported by anti-friction

bearings. A bearing of corrosion-resistant metal shall be provided on the shaft

outboard of the valve shaft seal or in the actuator housing to protect the valve shaft

seal from side thrust forces developed in the operating mechanism.

4.4.8.3 Lubrication. Housings shall contain seals to prevent the leakage of

lubricant regardless of position. Lubricants shall be suitable for year-round service

based on prevailing ambient temperature conditions.

4.4.8.4 Handwheel. Optional handwheels shall be so connected that opera-

tion by the actuator shall not cause the handwheel to rotate. Operation of the

handwheel will assume loss or isolation of power to the actuator. The handwheel

shall require a maximum actuator input force of 80 lb (356 N) on the rim at any

point through valve travel. The handwheel shall have an arrow and the word

“OPEN” integrally cast or permanently affixed indicating the direction to open the

valve.

4.4.8.5 Position indication. Position indication shall be accomplished using

an indicator dial or arrow.

4.4.8.6 Stop limiting devices. Valve actuators shall be equipped with adjust-

able, mechanical, stop limiting devices to prevent over-travel of the valve in the open

and closed positions.

4.4.9 Pneumatic quarter-turn vane-type actuators. Pneumatic quarter-turn

rotary actuators shall be of the vane-type design with a minimum operating pressure

rating of 150 psig (1.03 MPa).

4.4.9.l Actuator housing. Housing shall be of aluminum construction. The

interior and exterior surfaces of the housing shall be fusion-bonded epoxy.

4.4.9.2 Vane construction. Vane shall be of carbon steel construction and

shall be electroless nickel plated. Vane and output shafts shall be of one (1) piece

design.

4.4.9.3 Actuator output shafts. Actuator output shafts shall include Teflon-

impregnated bronze bushings backed by steel.

4.4.9.4. Vane seals. Vane seals shall be of a material suitable for air. Seal

housing contact shall be accomplished by using seal expanders. Seal expanders shall

be constructed of stainless steel to prevent corrosion on interior of actuator. Vane

seals shall seal both sides of the vane to isolate output shaft. No compressed air or

fluid shall be allowed at the output shaft.






4.4.9.5 Hardware. All stop screws and all case bolts and nuts shall be

stainless steel.

4.4.10 Hydraulic/pneumatic actuator application.

4.4.10.1 Operating pressures. Operating pressures with either a hydraulic or

pneumatic medium shall be maintained on the actuator driver mechanism at each

end of its stroke unless other means are provided to prevent actuator drifting.

4.4.10.2 Adjustable flow-control device. When specified by the purchaser,

actuators shall be equipped with adjustable flow-control devices at or near each port

of the actuator controlling the operating medium exhausting from the actuator.

Unless otherwise specified by the purchaser, the opening and closing speeds shall be

nominally set for a range of 30 sec to 60 sec. However, the maximum operating time

for pneumatic actuators without slave cylinders should be limited to not more than

5 sec per in. of stroke to avoid jerky operation. Final adjustments shall be made by

the purchaser to minimize line surges during normal operation.

4.4.10.3 Actuator requirements. Pneumatic and water-hydraulic actuators

shall not require more than 7-psi (48-kPa) pressure to cycle a complete stroke in each

direction before being connected to a valve or slide gate operating mechanism. Oil-

hydraulic actuators shall not require more than 15 psi (103 kPa) for the same type of

cycling.

4.4.10.4 Rod-seal protection. Actuators shall be equipped with externally

facing dirt wipers to protect the rod seals from dirt and other foreign materials. The

externally facing wiper will not be required if the rod is fully protected by a sealed

boot or a totally enclosed gasketed cover.

4.4.10.5 Working pressure. Actuator sizing shall be based on the minimum

driver-medium working pressure specified by the purchaser.

Sec. 4.5 Painting and Coatings

4.5.1 General. Actuators shall be shop coated. Coatings for special service

shall be as specified by the purchaser.

4.5.2 Internal surfaces. All ferrous internal surfaces, except finished working

parts, such as shafts and gears, surfaces subject to constant coating by lubricants or

working fluids, and corrosion-resistant metals, shall be shop cleaned and finish

coated. A light color shall be used to enhance inspection and maintenance.

4.5.3 External surfaces. All external surfaces, except machined surfaces, shall

be thoroughly cleaned and shop coated with a suitable primer or paint system to a





22 AWWA C540-02

dry film thickness of not less than 76 µm (3 mils). Machined surfaces shall be coated

with suitable rust preventive applied in accordance with the actuator manufacturer’s

recommendations.

SECTION 5: VERIFICATION

Sec. 5.1 General

Two types of tests are required: proof-of-design tests and performance tests. The

purpose of the proof-of-design test is to prove that the design, material selection, and

manufacture of the actuator are suitable for the purpose intended as defined by this

standard. The purpose of the performance test is to prove that each actuator is in

working order prior to shipment. Actuators shall meet the requirements for each type

of test.

Sec. 5.2 Proof-of-Design Tests

5.2.1 General requirements. One production sample of each electric-motor

actuator-unit housing size and quarter-turn hydraulic or pneumatic actuator body

size shall be tested. For cylinder actuators, one production sample from each of the

following bore sizes shall be tested: up to 5 in. (127 mm), more than 5 in. (127 mm)

and up to 8 in. (203 mm), more than 8 in. (203 mm) and up to 12 in. (305 mm),

and more than 12 in. (305 mm). If the actuator design is changed or modified to

affect its strength or function, the test shall be repeated.

5.2.2 Electric-motor actuator. The proof-of-design test for an electric-motor

actuator shall be performed at the rated torque for the unit housing size being tested.

Electric motor, gear ratio, and torque spring shall be selected to produce the

maximum rated torque (for the unit housing size).

5.2.2.1 Test procedure. The test shall incorporate the following parameters:

1. One stroke—30 sec.

2. One cycle—2 strokes (60 sec open–close–open).

3. One test—5,000 cycles.

4. Off time—10 min maximum between cycles.

5. Seating torque—rated torque, unit housing size.

6. Running torque—30 percent (minimum) of seating torque.








Each proof-of-design test shall consist of 5,000 cycles (open–close–open) spaced

a maximum of 10 min apart. The actuator shall run for 30 sec continuously to close

(seating by torque switch), then shall be reversed and immediately run for 30 sec

continuously to open (stopping by limit switch). Torque applied at seating shall equal

the rated torque (unit housing). Torque during the open or close stroke (run torque)

shall be 30 percent (minimum) of the seating torque. Limit and torque switches shall

be monitored for repeatability within 2.0 percent of travel and 5.0 percent of rated

torque, respectively. Contacts shall carry rated electrical load during testing and shall

be serviceable on test completion.

5.2.2.2 Test results. Failure of any component will not be allowed during

testing. Any adjustments, tightening of screws and bolts, or addition of lubricant

shall be detailed in the test report. The report shall include a complete description of

the action taken, why the service was required, and when the action occurred.

5.2.2.3 Test report. Each test report shall include at a minimum:

1. Actuator-unit housing size and model number.

2. Actuator serial number.

3. Motor torque, revolutions per minute (rpm), duty, and insulation class.

4. Gear ratios and efficiencies.

5. Drive-sleeve rpm.

6. Seating torque (unit-housing rated torque).

7. Running torque (30 percent rated torque).

8. Power, voltage, phase, and hertz.

9. Rated full load (amps).

10. Rated locked rotor (amps).

11. Running-torque amps (measured).

12. Seating-torque amps (measured).

13. Limit-switch (test) voltage and amps.

14. Limit-switch percent accuracy.

15. Torque-switch (test) voltage and amps.

16. Torque-switch percent accuracy.

17. Service requirements (during test).

18. Lubrication requirements (during test).

5.2.3 Hydraulic or pneumatic actuator. The proof-of-design test for a

hydraulic or pneumatic actuator shall consist of testing the actuator at rated pressure

for 5,000 complete cycles. Pressure shall reach rated pressure at the end of each





24 AWWA C540-02

stroke. Failure of any component during the test shall constitute failure of the test. As

part of the proof-of-design tests, those sizes stipulated in Sec. 5.2.1 shall be subjected

to a hydrostatic test with oil or water to a pressure equal to three times rated pressure.

The pressure shall be applied for a period of 5 min. No fluid leakage shall be allowed

from the body or rod seals. There shall be no evidence of detrimental or permanent

distortion of any part.

5.2.3.1 Test report. Each test report shall include the following as a

minimum:

1. Bore size.

2. Stroke.

3. Number of cycles.

4. Pressure.

5. Driver medium.

6. Results of hydrostatic test.

5.2.4 Quarter-turn hydraulic or pneumatic actuator. The proof-of-design

test for a quarter-turn cylinder actuator shall consist of the requirements of Sec. 5.2.3

for the cylinder and the following:

5.2.4.1 Test procedure. Each actuator size shall be given a torque test equal

to or greater than twice the rated torque, through one complete open–and–close

cycle. The design shall also be verified by cycle testing of one production sample of

each actuator body size through full cycles with full rated torque at the point of

unseating and a minimum of 30 percent of the rated torque during the open–and–

close stroke. The number of cycles shall be in accordance with Table 1.

5.2.4.2 Test results. Each test report shall include the following at a

minimum:

1. Actuator unit size and model.

2. Cylinder bore and stroke tested.


4. Rated torque.

5. Applied torques.

6. Results of examination.






Sec. 5.3 Performance Tests

5.3.1 General requirements. Each actuator shall be performance-tested prior

to shipment. If any component of the unit fails during testing, the malfunction shall

be corrected or repaired as required and the unit retested.

5.3.2 Electric-motor actuator. Electric-motor actuators shall be tested at the

specified application torque and rpm.

5.3.2.1 Test procedure. Each actuator shall be performance-tested to verify

conformity to specified operating conditions including

1. Voltage, phase, and frequency.

2. Stroke time (seconds).

3. Seating (or maximum dynamic) torque.

4. Seating load amps.

5. Torque-switch and limit-switch function.

Each actuator shall be cycled through at least two strokes (open–close and close–

open). Specified seating (or maximum dynamic) torque shall be applied during

10 percent of actuator travel in both directions. Actual stroke time shall be within

±10 percent of the specified stroke time. Limit-switch and torque-switch function

shall be verified in both directions. Torque switches shall be demonstrated to limit

torque output to a minimum of 120 percent of the seating torque at the maximum

setting and a maximum of 100 percent of seating torque at the minimum setting.

Amperes at running and seating loads are to be monitored and shall not exceed the

actuator manufacturer’s catalog ratings.

5.3.2.2 Test report. Each test report shall include the following at a

minimum:

1. Actuator-unit housing or frame size and model number.

2. Actuator serial number.

3. Power, voltage, phase, and frequency.

Table 1 Prototype actuator test cycles required

Torque Rangeft-lb (N-m) Number of cycles

Up to 3,750 (5,080) 10,000

3,751–6,250 (5,080–8,470) 05,000

6,251 and greater (8,470 or greater) 01,000





26 AWWA C540-02

4. Closed: Stroke time, seating (dynamic) torque, and seating (dynamic)

amps.

5. Open: Stroke time, dynamic torque, and dynamic amps.

5.3.3 Cylinder actuator. Each actuator shall be cycled a minimum of three

times from the fully closed to the fully opened position and the reverse to

demonstrate that the complete assembly, including controls, operates properly. The

maximum driver-medium pressure required to cycle the actuator at no load shall not

be more than 7 psi (48 kPa) for water-hydraulic and pneumatic cylinders or 15 psi

(103 kPa) for oil-hydraulic cylinders as stipulated in Sec. 4.4.7.3.

5.3.3.1 Oil-hydraulic actuators. Each completed actuator assembly shall be

tested at the rated pressure, pressurizing each port in turn. During the test there shall

be no leakage at the head or cap ends, the rod seals, or other static seals. There shall

also be no leakage past the piston seals or evidence of detrimental or permanent

deformation of any part. The duration of this test shall be sufficient to allow visual

examination for leakage and shall be at least 1 min.

5.3.3.2 Water-hydraulic and pneumatic actuators. Each actuator shall be

tested for function at 150 psi (1.03 MPa). There shall be no external leakage or

leakage across the piston. The duration of this test shall be sufficient to allow visual

examination for leakage and shall be at least 1 min. Pressure shall be applied

individually to the head port and cap port for this test. There shall be no evidence of

detrimental or permanent deformation of any part.

5.3.3.3 Test report. Each test report shall include the following at a

minimum:

1. Bore size.

2. Stroke.


4. Pressure.

5. Driver medium.

6. Results of operation and pressure tests.

Sec. 5.4 Test Certification

Certification of tests and copies of test reports shall be provided on request if the

request is made prior to the time of testing.






Sec. 5.5 Inspection and Testing

All work performed in accordance with this standard shall be subject to

inspection and approval by the purchaser. The purchaser shall at all times have access

to all places where actuators are being produced or fabricated or where tests are being

conducted. The purchaser shall be accorded full facilities for inspection and

observation of tests. Power actuators or parts rejected by the purchaser because of

failure to conform to the requirements of this standard shall be made satisfactory or

replaced.

If the purchaser is not at the plant, the actuator manufacturer shall, if requested

at the time the order is placed, certify that the required tests will be made. In this

case, no component or actuator shall be provided that has not been tested and found

to conform to the requirements of this standard. Copies of the test results shall be

provided if requested by the purchaser.

SECTION 6: DELIVERY

Sec. 6.1 Marking

A corrosion-resisting nameplate or nameplates containing the following data

shall be permanently mounted on the actuator housing or motor.

1. Manufacturer’s name.

2. Identifying model number and/or serial number.

3. Supply voltage or pressure.

4. For electric actuators:

a) Current draw.

b) rpm.

c) Motor rating (hp).

5. For pneumatic or hydraulic actuators:

a) Maximum supply pressure rating.

b) Cylinder or vane size.

Sec. 6.2 Packaging, Shipping, and Storage

Actuators, whether shipped assembled on slide gates or valves or shipped

separately, shall be fastened or cushioned in appropriate cartons, crates, or skids to

protect them from contact by other material during shipping or handling. Exposed







28 AWWA C540-02

male threads on actuators and controls shall be protected with tape or caps. All

openings into actuators or controls shall be closed by using caps or plugs. Electrical

enclosures that are not weathertight by design shall be protected against the elements

before and during shipment. If actuators must be lubricated in the field prior to

service, the instructions to this effect and the lubrication procedures shall be attached

to the exterior of the unit.

If actuators with electric components are to be stored outside or in an area

subject to temperature changes and condensation for any appreciable length of time

prior to service, the purchaser shall so advise the supplier so that proper precautions

can be taken. If it is necessary for the purchaser to take any precautions during

extended storage, such as connecting heaters to power service, exercising at intervals,

inspecting contacts before startup, blowing out supply lines, relubricating, or other

measures, the supplier shall so notify the purchaser prior to or at the time of

shipment.

NOTE: This standard is intended to cover normal domestic shipment (rail,

air, or truck), normal handling (hoists, cranes, or forklifts), and covered storage.

Impact from dropping or throwing containers, crates, and skids is not considered

normal. Other conditions may require special provisions that should be specified by

the purchaser.

Sec. 6.3 Affidavit of Compliance

Whether the purchaser has an agent at the plant or not, an affidavit may be

required from the supplier certifying that the power actuators provided comply with

all applicable provisions of this standard.




















1P-4.2M-43540-01/03-CM Printed on recycled paper.

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AWWA C540-02 Actuadores eléctricos para compuertas