AWWA C540-02 Actuadores Eléctricos para Compuertas

The Authoritative Resource for Safe Drinking Water
SM
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 Valves
and Slide Gates
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Copyright 2003 American Water Works Association, All Rights Reserved.
Approved by American National Standards Institute: May 21, 2002.
ii
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,
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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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CAUTION NOTICE: The American National Standards Institute (ANSI) approval date on the front cover of this standard
indicates completion of the ANSI approval process. This American National Standard may be revised or withdrawn at
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Science and Technology
AWWA unites the drinking water community by developing and distributing authoritative scientific and technological
knowledge. Through its members, AWWA develops industry standards for products and processes that advance public
health and safety. AWWA also provides quality improvement programs for water and wastewater utilities.
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Copyright 2003 by American Water Works Association
Printed in USA
iii
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)
J.W. Benson, Memphis Light Gas & Water, Memphis, Tenn. (AWWA)
T.W. Knowlton, SalemBeverly 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, WrightPierce, 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)
v
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
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 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
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
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), 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) 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.
ix
Class 160 starts per hour, maximum
Class 41,200 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
xi
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 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.
xii
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 standards@awwa.org.
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 openclose, 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
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 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
*
250Enclosures for Electrical Equipment (1,000 Volts
Maximum).
ANSI/NEMA MG1Motors and Generators.
ANSI/NFPA
70National Electrical Code.

ASTM A36Standard Specification for Carbon Structural Steel.
ASTM A48Standard Specification for Gray Iron Castings.
ASTM A108Standard Specification for Steel Bars, Carbon, Cold-Finished,
Standard Quality.
ASTM A123Standard Specification for Zinc (Hot-Dip Galvanized) Coatings
on Iron and Steel Products.
ASTM A126Standard Specification for Gray Iron Castings for Valves,
Flanges, and Pipe Fittings.
ASTM A153Standard Specification for Zinc Coating (Hot-Dip) on Iron and
Steel Hardware.
ASTM A216Standard Specification for Steel Castings, Carbon, Suitable for
Fusion Welding, for High-Temperature Service.
ASTM A276Standard Specification for Stainless Steel Bars and Shapes.
ASTM A351Standard Specification for Castings, Austenitic, Austenitic-
Ferritic (Duplex), for Pressure-Containing Parts.
ASTM A395Standard Specification for Ferritic Ductile Iron Pressure-
Retaining Castings for Use at Elevated Temperatures.
ASTM A436Standard Specification for Austenitic Gray Iron Castings.
ASTM A439Standard Specification for Austenitic Ductile Iron Castings.
ASTM A511Standard Specification for Seamless Stainless Steel Mechanical
Tubing.
ASTM A513Standard Specification for Electric-Resistance-Welded Carbon
and Alloy Steel Mechanical Tubing.
ASTM A516Standard Specification for Pressure Vessel Plates, Carbon Steel,
for Moderate- and Lower-Temperature Service.
ASTM A519Standard 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 A536Standard Specification for Ductile Iron Castings.
ASTM A743Standard Specification for Castings, Iron-Chromium,
Iron-Chromium-Nickel, Corrosion-Resistant, for General Application.
ASTM B85Standard Specification for Aluminum Alloy Die Castings.
ASTM B117Standard Practice for Operating Salt Spray (Fog) Apparatus.
ASTM B127Standard Specification for Nickel-Copper Alloy (UNS 04400)
Plate, Sheet, and Strip.
ASTM B135Standard Specification for Seamless Brass Tube.
ASTM B154Standard Test Method for Mercurous Nitrate Test for Copper
and Copper Alloys.
ASTM B164Standard Specification for Nickel-Copper Alloy Rod, Bar, and
Wire.
ASTM B179Aluminum Alloys in Ingot and Molten Forms for Castings from
Aluminum Casting Processes.
ASTM B240Specification for Zinc and Zinc-Aluminum Alloys in Ingot
Form for Foundry and Die Castings.
ASTM B505Standard Specification for Copper-Base Alloy Continuous
Castings.
CDA
*
CopperBrassBronze 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, nickelcopper 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. 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.
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 ActuatorsGeneral 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 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
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
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, openstopclose push buttons and position
indicating light(s) for openclose push buttons, indicating light(s), position feedback
device, localoffremote selector switch, and solid-state position comparator circuit
for modulating service.
Digitally controlled actuators must always include a localoffremote 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 Openclose 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
openstopclose 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 openclose 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 localoffremote, 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 420 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 ActuatorsGeneral 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 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.
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 actuators 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 actuators 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-m) 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-m) 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 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, 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-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. Nonmet al 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
ASTMD570.
4.4.6.1 Cylinder barrels. Cylinder barrels shall be fiberglass-reinforced plas-
tic 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. 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-m) 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 openclose, 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 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.
4.4.7.4.1 Physical. Hydraulic-water medium shall have dirt and scale parti-
cles 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 CaCO
3
)
shall be used unless otherwise specified. For potentially aggressive (low-alkaline)
waters, a water analysis that includes total hardness, pH, CO
2
, 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
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 m (3 mils). Machined surfaces shall be coated
with suitable rust preventive applied in accordance with the actuator manufacturers
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 stroke30 sec.
2. One cycle2 strokes (60 sec opencloseopen).
3. One test5,000 cycles.
4. Off time10 min maximum between cycles.
5. Seating torquerated torque, unit housing size.
6. Running torque30 percent (minimum) of seating torque.
Each proof-of-design test shall consist of 5,000 cycles (opencloseopen) 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 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.
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 (openclose 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 manufacturers 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 Range
ft-lb (N-m) Number of cycles
Up to 3,750 (5,080) 10,000
3,7516,250 (5,0808,470) 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. Manufacturers 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.
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.

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