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AWWA C540 02 Actuadores Electricos para Compuertas
AWWA C540 02 Actuadores Electricos para Compuertas
AWWA Standard
Power-Actuating
Devices for Valves
and Slide Gates
Advocacy
Communications
Conferences
Education and Training
Science and Technology
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AWWA Standard
This document is an American Water Works Association (AWWA) standard. It is not a specification. AWWA standards
describe minimum requirements and do not contain all of the engineering and administrative information normally
contained in specifications. The AWWA standards usually contain options that must be evaluated by the user of the
standard. Until each optional feature is specified by the user, the product or service is not fully defined. AWWA
publication 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 a
consensus of the water supply industry that the product described will provide satisfactory service. When AWWA revises
or withdraws this standard, an official notice of action will be placed on the first page of the classified advertising
section of Journal AWWA. The action becomes effective on the first day of the month following the month of Journal
AWWA publication of the official notice.
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Copyright 2003 American Water Works Association, All Rights Reserved.
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 of
approval:
Fred L. Hinker, Chair
Amzad 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)
(AWWA)
(NEWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(AWWA)
(NEWWA)
(AWWA)
(AWWA)
(AWWA)
*Liaison, nonvoting
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Copyright 2003 American Water Works Association, All Rights Reserved.
Producer Members
Robert Arnold, Rotork Controls Inc., Rochester, N.Y.
(MSS)
(AWWA)
(AWWA)
(VMA)
(AWWA)
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Copyright 2003 American Water Works Association, All Rights Reserved.
Contents
All AWWA standards follow the general format indicated subsequently. Some variations from this format
may be found in a particular standard.
SEC.
PAGE
SEC.
PAGE
Foreword
Requirements
Introduction..................................... vii
4.1
I.A
Background...................................... vii
I.B
History............................................. vii
4.2
II
4.3
Electric-Motor Actuators
II.A
Discussion........................................ vii
II.B
III
III.A
Manufacturer .................................. 6
4.5
Verification
5.1
General ............................................ 22
5.2
5.3
Performance Tests............................ 25
Standard
5.4
Test Certification............................. 26
General
5.5
1.1
Scope ................................................. 1
Delivery
1.2
Purpose .............................................. 2
6.1
Marking ........................................... 27
1.3
Application ........................................ 2
6.2
References.......................................... 2
6.3
Affidavit of Compliance................... 28
Definitions ........................................ 4
Modification to Standard.................. xi
IV
Table
1
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Copyright 2003 American Water Works Association, All Rights Reserved.
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 requirements 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 purchasers 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
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Copyright 2003 American Water Works Association, All Rights Reserved.
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
standards provisions are suitable for and compatible with that users 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), maximum 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) Openclose. Give frequency of operation and travel time duty cycle.
2) Throttling and Modulating. Give operating conditions, input signal to
actuator, and starts per hour.
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Copyright 2003 American Water Works Association, All Rights Reserved.
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Copyright 2003 American Water Works Association, All Rights Reserved.
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 speedcontrol 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, definitions, or terminology in this standard must be provided in the purchasers
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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Copyright 2003 American Water Works Association, All Rights Reserved.
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Copyright 2003 American Water Works Association, All Rights Reserved.
ANSI/AWWA C540-02
(Revision of ANSI/AWWA C540-93)
AWWA Standard
GENERAL
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Copyright 2003 American Water Works Association, All Rights Reserved.
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.
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 D570Standard Test Method for Water Absorption of Plastics.
ANSI B93.10Static Pressure Rating Methods of Square Head Fluid Power
Cylinders.
ANSI B93.29Fluid Power Systems, Dimensions for Accessories for Catalogued 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
AWWA C540-02
SECTION 3:
DEFINITIONS
*Copper Development Association Inc., Box 1840, Greenwich Office Park 2, Greenwich, CT 06836.
POWER-ACTUATING DEVICES 5
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. Openclose: 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.
AWWA C540-02
SECTION 4:
REQUIREMENTS
POWER-ACTUATING DEVICES 7
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 quarterturn 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 0F to 150F (17.8C to 65.6C). 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
POWER-ACTUATING DEVICES 9
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, opencloseopen or closeopen
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
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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
POWER-ACTUATING DEVICES 11
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AWWA C540-02
POWER-ACTUATING DEVICES 13
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 80-6008, 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 Nickelcopper 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 aluminumbronze parts subject to water contact shall be inhibited
against dealuminization by receiving a temper anneal at 1,200F (650C) 50F
(28C) 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.
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AWWA C540-02
POWER-ACTUATING DEVICES 15
4.4.4.3 Cylinder pistons. Pistons shall be bronze, suitable nonmetallic material, 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-m) finish or smoother.
4.4.4.5 Piston-rod bushing. Bushings shall be bronze or nonmetallic materials 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 boltedflange 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 actuators 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-m) 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, suitable 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
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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) minimumyield-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-m) 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. No n m e t a 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 plastic having an inside surface finish of 20 microinches (0.508-m) 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. Fixedmounted 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.
POWER-ACTUATING DEVICES 17
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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 openclose service. Compressed air shall have dirt and scale
particles and water droplets removed to no larger than 40 m (1.6 mils). It is
recommended that the purchaser provide air-line lubricators for an openclose
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 m
(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 m (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 130F
(54.4C) and pressures up to 150 psi (1.03 MPa) shall be used unless otherwise
specified.
4.4.7.4 Water-hydraulic medium requirements.
POWER-ACTUATING DEVICES 19
4.4.7.4.1 Physical. Hydraulic-water medium shall have dirt and scale particles removed to no larger than 20 m (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 purchasers specifications.
4.4.7.4.3 Temperatures/pressure. Hydraulic-water temperatures up to 125F
(51.6C) 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 m. Viscosity of hydraulic oil shall be 135 to
165 SSU (Standard Saybolt Universal) at 100F (37.8C) 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 200F
(93.3C) 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 130F (54.4C) 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 cylinders 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
POWER-ACTUATING DEVICES 21
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. Oilhydraulic 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.
22
AWWA C540-02
dry film thickness of not less than 76 m (3 mils). Machined surfaces shall be coated
with suitable rust preventive applied in accordance with the actuator manufacturers
recommendations.
SECTION 5:
VERIFICATION
POWER-ACTUATING DEVICES 23
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 openandclose
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 openand
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.
3. Number of cycles.
4. Rated torque.
5. Applied torques.
6. Results of examination.
POWER-ACTUATING DEVICES 25
Table 1
(N-m)
Number of cycles
Up to 3,750
3,7516,250
6,251 and greater
(5,080)
(5,0808,470)
(8,470 or greater)
10,000
05,000
01,000
26
AWWA C540-02
4.
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.
3. Number of cycles.
4. Pressure.
5. Driver medium.
6. Results of operation and pressure tests.
POWER-ACTUATING DEVICES 27
SECTION 6:
DELIVERY
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.
AWWA is the authoritative resource for knowledge, information and advocacy to improve the quality and supply of
drinking water in North America and beyond. AWWA is the largest organization of water professionals in the world.
AWWA advances public health, safety and welfare by uniting the efforts of the full spectrum of the drinking water
community. Through our collective strength we become better stewards of water for the greatest good of
the people and the environment.
1P-4.2M-43540-01/03-CM