ABU DHABI MUNICIPALITY

SEWERAGE DIRECTORATE
GENERAL SPECIFICATION
MECHANICAL WORKS

STANDARD SPECIFICATION SECTION 07020

VALVES, PENSTOCKS & ACTUATORS

Document No.

Revision

Date

DIVISION 7

SD/GS/M&E/07020

00

April. 2003

Valves, Penstocks & Actuators

Section 07020

Page 1 of 16

General Specification for M&E Works

Sewerage Directorate
Abu Dhabi Municipality
INDEX................................................................................................................................................................. PAGE NO.
1

DOCUMENT CONTROL SHEET .............................................................................................................................. 3

VALVES ................................................................................................................................................................... 4

1.1

General......................................................................................................................................................... 4

2.2

Application.................................................................................................................................................... 5

2.3

Valve Identification ....................................................................................................................................... 5

2.4

Replacement ................................................................................................................................................. 6

2.5

Sluice Valves ................................................................................................................................................ 6

2.6

Knife/Slide Gate Valves ................................................................................................................................ 6

2.7

Butterfly Valves............................................................................................................................................. 7

2.8

Eccentric Plug Valves................................................................................................................................... 8

2.9

Ball Valves .................................................................................................................................................... 8

2.10

Diaphragm Valves ...................................................................................................................................... 9

2.11

Reflux Valves.............................................................................................................................................. 9

2.12

Swing Check Valves................................................................................................................................... 9

2.13

Wafer Check Valves ................................................................................................................................. 10

2.14

Ball Type Valves....................................................................................................................................... 10

2.15

Nozzle Ring Check Valves ...................................................................................................................... 10

2.16

Air Valves ................................................................................................................................................. 11

2.17

Process Control Valves............................................................................................................................ 11

2.18

Float Valves .............................................................................................................................................. 11

2.19

Safety Valves ............................................................................................................................................ 11

2.20

Anti-Vacuum Valves/Devices ................................................................................................................... 11

2.21

Chlorine Valves ........................................................................................................................................ 12

PENSTOCKS (including sluice gates) .................................................................................................................. 12

3.1

General........................................................................................................................................................ 12

3.2

Pressure Seals............................................................................................................................................ 13

3.3

Drive Spindle and Nut................................................................................................................................. 13

3.4

Fixing Bolts................................................................................................................................................. 14

3.5

Headstock Pillar.......................................................................................................................................... 14

ACTUATORS ......................................................................................................................................................... 14
4.1

Electric........................................................................................................................................................ 14

4.2

Pneumatic................................................................................................................................................... 16

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Valves, Penstocks & Actuators

Section 07020

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Sewerage Directorate
Abu Dhabi Municipality

DOCUMENT CONTROL SHEET

Revision No.

Date

Revision Description / Purpose of Issue

00

Jan 2003

General update of CDM specification for Valves, Penstocks

and Actuators. Issued for Implementation.

01

01A

02

02A

03

03A

04

04A

Approved for Implementation:

_______________________________________

Document No.

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00

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Valves, Penstocks & Actuators

Section 07020

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General Specification for M&E Works

Sewerage Directorate
Abu Dhabi Municipality

2
2.1

VALVES
General

a)

Valves shall be suitable for their application, media being passed, sized for a maximum fluid
flow of 2.5 meters/sec, double flanged, and installed in such a manner as to allow ease of
operation and maintenance. They shall be designed to withstand higher velocities of 3.5m/sec.

b)

All valves shall be works tested and capable of withstanding the same test pressures as the
pipeline or vessel on which they operate. The minimum test pressure shall be 10 bar.

c)

The use of dissimilar metals in conjunction with a corrosive environment shall not be permitted,
e.g. steel pipes and non-ferrous valves.

d)

Valves used in water treatment process plant shall be suitable for use with the chemicals
associated with the process, e.g. Chlorine, coagulants, polyelectrolyte, lime, etc.

e)

Valves used in sewage treatment process plant shall be suitable for use with unscreened
sewage which includes grit, grease and un-macerated rags, etc. Rubber faced valves are not
permitted.

f)

Valves installed within buildings shall be clockwise closing whether geared or not. Handwheels
shall have the direction of opening and closing cast thereon. Bituminous paints shall not be
applied to the handwheel.

g)

Valves and Penstocks located outside buildings shall have non-rising spindles, and fitted with a
locking device where operation will be critical to the process/plant being controlled/isolated.

h)

Valve gearboxes shall be provided where necessary to allow handwheel operation at maximum
differential pressure. Gearboxes are to be fully enclosed.

i)

Cast Iron valves shall be high duty close-grained grey cast iron, to BS 1452 or equivalent,
Grade 220 minimum, and an arrow cast onto the body showing direction of flow.

j)

The body ends shall be sealed for transit and storage.

k)

All valves shall be capable of drop-tight isolation of the free end of an unsupported pipe and be
capable of manual operation under maximum head conditions.

l)

Valve selection shall be as follows:i) Pump Isolation - Wedge Gate Sluice, or in the case of potable water and irrigation, water
butterfly valves may be used.
ii) Potable Water & Irrigation water Control/Isolation - Butterfly, Ball, Eccentric Plug, Globe,
Axial Sleeve or Roll Seal. Butterfly valves for tertiary treatment filter control.
iii) Sludge Control - Eccentric Plug or Knife Edge Gate.
iv) Chemical Dosing - Diaphragm or Ball, with the exception of chlorine gas isolation valves

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Abu Dhabi Municipality
that shall be tapered plug valves.
v) Slurry lines (e.g. Lime) - Weirless Diaphragm.
vi) Sampling - Diaphragm or Ball.
vii) Gas Control - Diaphragm or Ball.
viii) Non-return or Reflux valves shall be fitted downstream of all pumping plant, and shall be
suitable for use with the medium being pumped.
m)

Valves for gas application shall be firesafe type.

n)

Depending on the size, and hence weight of a valve, it shall be supported independently of the
pipes which they connect. In any event valves > 300mm NB shall be independently supported.

o)

Vandal and weather proof clear polycarbonate tube covers shall be securely fitted to protect the
threads of rising stems and spindles. Tubes shall be clearly and permanently engraved to indicate
the position of the valve. A tube cap shall be provided.

2.2

Application

a)

Where pressure differential is expected to create difficulty in the operation of a valve, ball thrust
collar, gear or motor operation shall be provided. Gearing shall be supplied where necessary to
ensure that the required operating force applied by hand to the rim of the wheel does not exceed 25
kgf. By-pass valves are permitted as an alternative where hydraulic balance is possible and
becomes a pre-condition to valve opening. Gearboxes shall be mandatory above 350mm NB.

b)

If the handwheel cannot be readily accessed, extension spindles, headstocks and foot brackets shall
be provided where specified. Wherever feasible, designs should ensure readily accessible valves.

c)

Valves up to 40mm inclusive shall have screwed, socket-welded or flanged ends according to service
conditions and pipework layout.

d)

Valves larger than 50mm shall have flanged ends but where they are not subject to frequent removal
screwed valves shall be used according to service conditions and pipework layout.

e)

For sewage applications for valves > 300mm NB, valves shall be of the rising spindle type unless
subject to submergence, and for potable water or irrigation water applications of the non-rising type.
Extended spindle installations of the rising type shall be provided for all motorised/actuated valves.

2.3
a)

Valve Identification
All valves shall be identified by permanently fixed traffolyte labels/brass plates which shall identify the
valve number, and function, and be attached by cable ties to an integral part of the valve - not the
handwheel or lever. Information on the tags shall be;
NO
NC
NT
NA
SOC

Normally open
Normally closed
Normally throttled
Normally automatic
Set on commissioning

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Section 07020

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Sewerage Directorate
Abu Dhabi Municipality

2.4
a)

2.5

Replacement
Where replacement of existing valves with new or alternative valves is specified in the Contract then
the Contractor shall be responsible for the provision of double-flanged spool-pieces, as required, and
their protective finish. Restoration of any finish damaged in the removal of the old valves and the
supply of gaskets, nuts, bolts and washers shall be included.

Sluice Valves

a)

Double flanged sluice valves shall be provided as "boundary" valves on all elements of the process
stream. For PN 25 bar valves, the additional requirements of BS 5150 or equivalent shall apply.

b)

Sluice valves shall have bodies of high quality cast iron and shall be fitted with resilient seals up to
350mm NB. Above 350mm the wedge shall be of cast iron with renewable wedge face rings of
gunmetal and the spindle shall be of stainless steel for sewage, and aluminium bronze, nickel bronze
or stainless steel 316L for potable water/ irrigation water.

c)

Sluice valves shall have rising spindles unless otherwise specified in the particular specification.

d)

Where sluice valves above 350mm bore are mounted with the spindle in the horizontal plane, valve
bodies shall be fitted with renewable gunmetal machined gate slides and the gates with renewable
hard bronze shoes accurately machined to reduce sliding fraction.

e)

Extension spindles shall be of stainless steel and be compliant with the specification for valve stems.
They shall be of the muff type and shall be drilled and provided with a nut and bolt for securing the
spindle to the valve stem, which shall likewise be drilled to accept the bolt.

f)

Sluice valves for sewage applications shall be fitted with bronze wedge gates.

g)

All sluice valves shall be fitted with cast iron hand wheels unless otherwise specified. Stem caps
shall be provided on all valves detailed for key operation and shall be secured with socket headed set
screws.

h)

Sealing shall be so arranged that replacement can be accomplished with ease and shall not require
the removal of the valve from the pipeline. Unless otherwise specified stem sealing shall by toroidal
'O'ring seal for water. For sewage a conventional soft packed stuffing-box arrangement is required,
and the packing shall be non-asbestos.

i)

The dimensions of a gate valve fitted with a by-pass valve shall not exceed the basic dimensions set
down in BS 5150 or equivalent and BS 5163 or equivalent.

j)

Valves of 500mm nominal diameter (300mm if power actuated), or larger shall be fitted with a wedge
release jacking screw and locknut.

2.6

Knife/Slide & Pinch Gate Valves

a)

Knife slide/gate valves shall present a virtually full clear bore opening to the flow when fully open.

b)

The Valve body shall be cast, ductile iron or SG iron, incorporating an elastomer body seal captive
between the body valves in a closed loop. The seal shall contact the slide along its edge, being
positively guided by the compressed seal. No cavity between the edge of the slide and the body is

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Abu Dhabi Municipality
permitted. The body shall incorporate specially-contoured flush-out corners in the invert, such that,
any solids in the blade guides pushed down to the invert as the slide is closed are flushed into the
flow by the increased velocity of the medium. The valve body shall have increased clearance in the
chest area to minimise the possibility of solid material causing the valve to jam due to compaction in
that location.
c)

The valve slide shall be stainless steel, ground on its faces and two long edges, and shall have a
leading edge radius larger than the valve bore radius, incorporating a single chamfer to give a cutting
action through solids in the line onto the body flush invert, ensuring at all times a complete bubbletight, non compacting shut-off.

d)

The body/slide sealing system shall be outside the fluid flow path through the valve so that it is
protected from abrasion and erosion damage caused by solids and grit in the flow to ensure long,
maintenance-free seal life.

e)

Sealing to atmosphere shall be replaceable elasstometer sealing elements in the chest of each side
of the body, protected by brass scrapers against damage by entrained abrasive material. In the event
of leakage, adjustment of the sealing elements shall be effected by the introduction of a grease
compound behind the elastomer section through access tapping in the valve body edge: this
operation shall be carried out without the need for special tools or packing injectors.

f)

The valve shall be suitable for bi-directional flow, and shall give tight shut-off against the full
unbalanced head acting on either side of the closed slide.

g)

The valves shall be of bonnet less construction, and shall have operating mechanisms supported on
either a robust open cast iron hood or on a minimum of four steel pillars to give strength, rigidity and
structural integrity.

h)

Means of locking the valve in the open/closed positions shall be provided.

2.7

Butterfly Valves

a)

Butterfly valves may be used for potable water and irrigation water, and are not permitted for use in
raw waters and sewerage application

b)

All butterfly valves shall be of the cast iron, or ductile iron, and of the bonded rubber lined type, be
hand wheel operated, and where applicable, be electrically operated with actuators. Gearboxes shall
be used for valves over 350mm NB. Butterfly valves shall be suitable for ON/OFF tight shut-off
service, against the maximum differential pressure across the valve in either direction of flow. Bodies
shall be cast iron. Valves with a replaceable rubber liner may be considered by the Engineer,
providing the means of locking and holding the liner in place is positive and acceptable.

c)

The bonded liner shall be EPDM for valves in continuous use and be extended to act as the flange
seal.

d)

Discs shall be stainless steel or aluminium bronze with stainless steel shafts.

e)

The body parts shall be circular and the diameter not less than that of the nominal pipe bore.

f)

All wetted parts shall be suitable for the service conditions, this applying to the resilient seat, disc or
any disc coating and shaft bushings.

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Abu Dhabi Municipality

g)

On "Swing-through" pattern butterfly valves, mechanical stops shall be fitted either to the valve or the
actuator to prevent over-travel. Where a reduction gearbox is fitted the stop shall be on the input side
of the gearbox. In addition, the interference between disc and liner/seat shall be such that positive
seating is achieved, both for manual operation and for electric actuator operation when end travel in
the closed position is stopped by limit switch and/or torque switch.

h)

Positive seating shall be achieved over a comparatively wide seating angle so that the setting of
valve actuator limits (i.e. mechanical end stop, and stop limit and signalling limit switches) is easily
achieved and is repeatable for prolonged periods of service, without the need for re-adjustment.

i)

Manually operated valves shall be fitted with a quadrant ratchet plate or locking plate to facilitate
manual setting.

j)

The body parts shall be circular and the diameter not less than that of the nominal pipe bore.

k)

The shaft may be in one piece or attached as two stub ends on opposite sides of the disc. The
means of attachment of the shaft to the disc shall be by using fixings in a homogeneous corrosionresistant material of a pattern which precludes the assembly becoming loose in operational service.
Grub screws, pins (parallel or taper) or clamps are not acceptable. Self-lubricating PTFE faced
bearings with 'O' ring seals shall be provided.

l)

Valves shall be provided with suitable stops to prevent movement of the shaft beyond the limits
corresponding to fully open and fully closed position of the disc.

2.8

Eccentric Plug Valves

a)

Eccentric plug valves shall be double-flanged, and where required by the contract, be provided with
electric actuation. Gearboxes shall be used for valves > 350mm NB.

b)

The valve body shall be cast iron with Ni-resist plug and resilient seat face. The spindle shall be
stainless steel supported in heavy-duty corrosion resistant bearings. The closing action shall be by the
plug pressing on a raised seat and the plug shall be retained within the valve body by a securely
bolted bonnet.

c)

In the open position the plug shall be out of the flow and provide a straight flow path through the
valve, and Position indication shall be provided.

d)

Gland replacement shall be accomplished with the minimum of dismantling. Asbestos packing is not
permitted.

e)

Position indicators shall be provided

2.9

Ball Valves

a)

Ball valves shall be permitted on pipeline diameters of 50mm or less e.g. Air / gas dosing lines etc.
Ball valves shall be fitted with limit stops.

b)

The ball and body shall be arranged to provide straight through flow when the valve is fully open

c)

Valve bodies shall be stainless steel. Cast iron bodies are permitted provided they are fitted with a

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stainless steel liner or are rubber lined. The ball and stem shall be stainless steel and seats shall be
PTFE. The valve stem shall be designed such that thrust is taken by the shaft and not via the ball
and seats. Body material shall be suitable for the chemical being handled.
d)

Non-metallic ball valves of uPVC or ABS are permitted in association with pipework of the same
material.

e)

Both metallic and non-metallic valves shall be three-piece pattern to facilitate replacement of the ball,
seat, backing ring etc. without dismantling of the pipe work.

2.10

Diaphragm Valves

a)

Diaphragm valves shall be of the straight through weirless type and are required on all slurry and
sampling lines. The diaphragm shall be a reinforced, flexible moulding directly fixed to the valve
spindle compressor. Provision shall be made for the replacement of the diaphragm which shall be
carried out without the need to remove the valve from the line.

b)

Position indicators shall be provided

2.11
a)

2.12

Reflux Valves
Reflux valves shall be supplied as follows:i)

In the horizontal section of each pump delivery line.

ii)

On any process line where reverse flow would be detrimental to equipment or process (inc.
sludge, air, gas etc).

Swing Check Valves

a)

Swing check valves shall be double flanged with cast iron bodies. In foul sewage the valves shall be
constructed to allow solid matter to fall clear of the valve flap and shall allow 100mm minimum
passing capacity. A hatchbox shall be provided immediately downstream of the valve in storm
sewage installations.

b)

Reflux valves shall be suitable for operating in the horizontal plane unless otherwise specified

c)

They shall be of the quick acting single door type designed to minimise slam on closure by means of
heavy gunmetal-faced doors weighted as necessary. The valves shall be fitted with renewable
gunmetal door sealing faces which shall be positively fixed. The door hinge pin/shaft shall extend
through a sealing gland on the side of the body and be fitted with an external lever to permit back
flushing. Glands shall be of the stuffing box type with the exception that for valves below 450mm
bore they may be of the o ring type. Valves shall have a non-slam closing characteristic in reverse
flow which shall be accomplished by use of the inertia of the valve. Weights may have to be added
to the lever arm to accommodate shorter closing times.

d)

All valves shall embody the following features:i)

Detachable cover plates of ample dimensions to facilitate inspection and withdrawal of the
flaps.

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Sewerage Directorate
Abu Dhabi Municipality
ii)
iii)
iv)
v)
vi)

vii)

2.13

Cast iron flaps fitted with gunmetal seat faces to close at an angle not more than 800 to the
axis of the pipe.
The flap seating faces shall mate accurately with the gunmetal renewable seating rings in the
valve body.
Ample pockets below the flap into which may fall any solid matter which might otherwise
prevent the flap from closing.
Suitable stops or other means to prevent the valve opening to an angle of less than 300 with
the axis of the pipe.
The flap shall be hung from, and positively secured to a stainless steel pin. The hinge
pin/shaft shall preferably be square in section to ensure positive location of the door. If
circular shafts are utilised the back flushing lever shall be located on a squared section, the
diagonal dimensions of which shall be equivalent to the full diameter of the shaft. Both door
and lever shall be positively and securely fixed to the hinge pin/shaft. Grub screws, pins
(parallel to taper) or clamps are not acceptable. All internal fixing devices shall be of stainless
steel.
Where specified, limit switches (Proximity type) shall be fitted to all reflux valves with external
lever arms. The proximity switch shall be of the metalclad type with sealed actuator and
cable entry. Cam operated micro-switches are not acceptable. Enclosures shall have a
minimum standard of IP54 and pre-wired with an adequate length of armoured cable.
Proximity switches shall be capable of working directly into 110 Volt a.c. control relay circuits
without the need for specialized proximity switch relay/amplifiers. Proximity switches should
be normally closed, opening when the reflux valve opens.

Wafer Check Valves

a)

Where required by the Contract, and particularly where rapid return of surge pressure waves is
expected, wafer check valves of the dual-flap, spring-assisted type manufacture, shall be used in
potable water, irrigation water and air and gas line applications. Such valves are not acceptable for
sewage.

b)

The valve body shall be cast iron, with stainless steel hinge pin, return spring, resilient viton seat and
discs of stainless steel. The movement of the sealing plate shall not lead to scuffing of the seat
material.

2.14
a)

2.15

Ball Type Valves

Where specified, Ball type non-return valves and shut off valves are permitted. In each case the
body shall be of 316L stainless steel and provide straight through flow when the valve is fully open.

Nozzle Ring Check Valves

a)

Nozzle ring check valves are only permitted where identified by a special surge analysis study. They
shall be slam-free operation with minimum headloss.

b)

Seat and disc materials shall be zinc free bronze and the return springs shall be 18/8 chromium nickel
steel.

c)

Internal surfaces of the valve shall be coated with approved epoxy paint.

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2.16

Air Valves

a)

The air valves shall be either of the "dual" large orifice type having a float operated large discharge
orifice and a lever operated small discharge orifice, or of the small orifice type having a float operated
small discharge orifice, and designed to prevent clogging of the floating mechanism.

b)

The air valve float chamber and float chamber cover shall be of cast iron with all other parts of noncorrodible materials. All orifices shall be located well clear of the liquid level in the float chambers,
and designed to prevent sedimentation of floating solids. Valve bases shall be as specified.

c)

The air valves shall be provided with separate isolating valves and drain plugs. Air valves with 'builtin' isolation facility are not permitted. Air release valve installation used for sewage pumping
applications shall have the chamber drain to be piped to an adjacent wet well or sewer.

2.17

Process Control Valves

a)

Process control valves such as pressure regulating, reducing or sustaining, shall be self-operating of
the globe valve pattern. As an alternative sleeve type or diaphragm valves and actuated valve
systems may be offered for the Engineers approval.

b)

The valves shall be hydraulically operated and pilot controlled in-line with the minimum of moving
parts. Pilot control shall be a direct-acting pressure operated, spring loaded valve designed to permit
flow into and out of the control space in controlling around the valve set point. Adjustment shall be
accomplished by an easily accessible thread adjuster on the pilot. Self cleaning strainers shall be
provided to protect the control system.

c)

Control Valves shall be sized, and the characteristic selected, to ensure adequate control at both
maximum and minimum flow. Back flow prevention shall be provided.

d)

Valve position transmitters (potentiometers etc.) shall be fitted in instances of open-loop control or
valve positioning applications.

2.18
a)

2.19
a)

2.20
a)

Float Valves
Float operated valves shall comply with the quoted standards, in the standards Section of this
Specification.

Safety Valves
Safety valves for compressed air or other process fluid applications, shall comply with the quoted
standards, in the standards Section of this Specification.

Anti-Vacuum Valves/Devices
Anti vacuum valves and devices shall be used for the prevention of contamination of potable water
by backflow. Such devices shall be used in series with a break pressure portable water tank or
sewerage pumping stations and sewerage pumping stations and sewerage treatment works.

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2.21

Chlorine Valves

a)

Chlorine gas isolation valves shall be a two way PTFE taper plug valve suitable for use with dry
chlorine. The body shall be of LCB carbon steel and plug of monel metal.

b)

An automatic air operated isolation valve shall be provided and be spring return, giving fail safe
operation in the event of loss of air supply.

c)

The Contractor shall be responsible for the air supply to the valve. The supply line shall incorporate
a moisture trap and drain located as near as possible to the electrically operated solenoid valves to
be used for isolation valve control.

d)

These valves shall operate from a 110 volt 50 Hz electricity supply and shall be mounted outside the
control box. Valve terminal enclosures shall be fully shrouded and fitted with a propriety cable
compression gland. Final connection to these valves shall be via short lengths of flexible multicore
cable from an adjacent termination box.

e)

The discharge from drums shall be protected by an automatic isolation valve system. The system
shall either be a proprietary system, or it shall comply with the following Clauses.

f)

The automatic control of the isolation valve system shall be from the gas leak detection equipment.

g)

For gas leak testing purposes, a remotely mounted manual opening facility shall be provided
for each isolation valve. These shall be spring return push buttons with engraved labels "Press
and Hold to Open Drum No 1 (No 2) Valve" and shall be incorporated into a shutdown control
panel (mounted in a safe area) with the following features.
i)
ii)
iii)
iv)
v)
vi)
vii)

3
3.1

Lamp (Green)
Lamp (Green)
Hand/Off/Auto Selector
Hand/Off/Auto Selector
Push Button
Push Button
Push Button

Drum No 1 Valve Open

Drum No 2 Valve Open
Drum No 1 Valve
Drum No 2 Valve
Press and Hold to Open Drum No 1 Valve
Press and Hold to Open Drum No 2 Valve
Reset System

PENSTOCKS (including sluice gates)

General

a)

Penstocks shall be of robust design, suitable for application and construction to be capable of
resisting deflection under the worst operating head conditions. Each penstock shall be provided with
a suitable handwheel of adequate diameter for the duty required.

b)

Penstocks shall carry identification marks and/or brass plates which identify the penstock number
and function.

c)

All penstocks shall be clockwise closing.

d)

Gearing shall be supplied where necessary to ensure that the required operating force applied by
hand to the rim of the wheel does not exceed 25 kgf. If the handwheel cannot be readily accessed,

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extension spindles, headstocks and foot brackets shall be provided where specified.
e)

Penstocks shall be fabricated stainless steel 316L. Where applicable the penstock shall be
electrically actuated. The handwheel shall have the direction of closing cast thereon. Bituminous
paints shall not be applied to the handwheel.

f)

Penstocks spindles specified to be key operated shall be fitted with stem caps. The caps shall be
drilled and each provided with nut and bolt for securing to the spindle which shall likewise be drilled
to accept the bolt. Where caps are fitted they shall be supplied complete with operating tee key. The
extended spindle shall be such that the tee key will be operated at 0.9-1.2 metres above floor level

g)

The penstocks shall be supplied complete with all accessories, fittings, fixing bolts, nuts and washers
ready for installation. Fixing nuts and bolts shall be supplied by the manufacturer and shall be of
stainless steel 316L.

h)

The penstocks shall be wall or channel mounted full frame "Flush Invert" type suitable for extended
operation.

i)

They shall offer excellent corrosion resistance, be lightweight in operation and require minimum
maintenance.

j)

The doors shall be designed for ON or OFF seating pressures, suitable for an off-seating head of
8.5m. The seals shall be watertight under these conditions for head and direction of flow.

k)

Thrust tubes shall be provided between the penstock frame and headstock in order to absorb the
thrust in both directions of operation. Thrust tubes shall incorporate all necessary fixing brackets and
spindle guide plates.

3.2

Pressure Seals

a)

The unseating sides of the frames shall be fitted with adjustable pressure seals. Frame seals shall
be EPDM and shall be fitted with corrosion resisting retaining strips and stainless steel 316L fixing
bolts. The seals shall be readily adjustable in situ using adjustable stainless steel fasteners which
shall be replaceable. The seals shall not project into the flow through the penstock aperture.

b)

The invert seal shall be EPDM.

3.3

Drive Spindle and Nut

a)

Penstocks shall be of the rising spindle type with the lifting bracket securely bolted to the top of the
door with stainless steel fasteners. The spindles shall be manufactured from stainless steel,
machined all over, with a machine cut robust trapezoidal or square form thread, operating in a
gunmetal nut. Polyethylene or similar materials are not permitted.

b)

The rising spindle shall be protected by a protection tube complete with position indicator end cap
and grease nipple. Where the spindle length exceeds 2.5m, guide brackets shall be provided for the
drive spindle and shall be bushed with aluminium bronze or similar non-ferrous material. These shall
be of the split bearing type.

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DIVISION 7

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Abu Dhabi Municipality

3.4
a)

3.5

Fixing Bolts
The penstock frame shall be fixed by stainless steel anchor bolts or encapsulated epoxy resin
bonded type. The design of anchor bolts shall be such that a minimum of civil preparation will be
necessary for satisfactory erection of the penstock.

Headstock Pillar

a)

Fabricated mild steel or cast iron pillars shall be provided for the mounting of the drive gear on the
penstock.

b)

The penstock frame shall be fabricated from 316 stainless steel sections. All welds shall be
continuous and adequate drainage of hollow sections shall be provided where applicable. Any
strengthening of doors by the provision of ribs and gussets shall be carried out by welding and not by
bolting

c)

The penstock door shall be stainless steel sandwich construction. The door shall be stiffened by a
steel matrix in a chemically bonded filler of rigid cellular polymer. The matrix shall be grit blasted
before polymer filling. Both outer faces of the door shall be protected with stainless steel sheeting.

d)

The door shall have sufficient strength to withstand the working pressures without significant
deflection or distortion.

e)

The side sealing faces may consist of simple metal to metal contact between the door and frames or
of synthetic rubber seals and plastic guides as necessary to withstand the required working pressure
without leakages.

f)

Penstocks shall be prepared and painted in accordance with the standard protection from corrosion
Section of this specification.

ACTUATORS

4.1

Electric

a)

Valve actuators shall be directly mounted onto and supported by the valves which they control
unless the valve is underground where the actuator shall be mounted at coping level. They shall be
suitable for remote Automatic control and shall also incorporate means for local manual operation
using a handwheel or lever. Actuators shall have integral starters and control equipment, unless the
actuator motor is of a size that necessitates a panel mounted starter, in which case it will be
specified in the particular specification.

b)

The output shaft shall be hollow to accept a rising stem and incorporate thrust bearings of the ball or
roller type.

c)

The design shall permit the gear case to be opened for inspection or disassembled without releasing
the stem thrust or taking the valve out of service.

d)

Valves stems and threads shall be provided with grease lubrication, rising spindle valves being
protected with a totally enclosed grease packed cover tube.

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April. 2003

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General Specification for M&E Works

Sewerage Directorate
Abu Dhabi Municipality
e)

The actuator shall be fitted with a drive bushing which is easily detachable for machining to suit the
valve stem or gearbox input shaft. Bushing shall be fitted in the base of the actuator to enable
standard length valve stems to be used.

f)

Only two categories of sealing are permitted:

1.
2.

UK BASEEFA certified for EExdIIBT4 CENELEC Norm EN50018, BS5501 for defined
hazardous locations; or
Watertight, dust-tight complying with the requirements of BS 5490 IP67 or better.

g)

Actuators shall be suitable for pedestal mounting and interchangeable without removal of the
associated valve, penstock, pedestal, etc.

h)

Sealing of static joints shall be by 'O' ring on moving components to prevent leakage of lubricant
from the machine.

i)

The actuator shall provide Double Sealing between the terminal compartment and the internal
electrical elements of the actuator, fully protecting the motor and all other internal electrical elements
of the actuator from ingress of moisture and dust when terminal cover is removed on site for cabling.

j)

For control purposes limit switches shall be fitted to the actuator at both the closed and open
positions of the valve. Limit switches shall also be fitted for signalling purposes. All these shall be
fitted internally. Limit switches contacts shall be volt-free. The switch contact rating shall be 5
amps, 250 volts AC, 30 volts DC. Valve position shall be clearly marked externally on the actuator.

k)

The actuators shall be sized so that they develop sufficient torque to reliably seat/unseat the valve or
penstock off its seat, and to provide adequate torque throughout its operating range. The torque
output must be at least 20% more than is required under maximum operating conditions (i.e.
maximum differential head). The drive shall incorporate a lost motion hammer blow feature.

l)

Adequate overload protection shall be provided to prevent actuator motor damage in the event of
seizure. This shall either be in the form of torque switches, or over-temperature thermostats. The
torque switch shall latch out on operation, and to be reset by driving in the opposite directions. A
mechanical latch shall be provided to prevent the open torque switch tripping while the initial
unsealing hammer blow is applied.

m)

The setting of the torque and limit switches shall be able to be carried out without the need to
remove any electrical compartment covers.

n)

Adjustable mechanical limit stops shall be provided for open and closed positions of actuators.

o)

Actuators supplies shall be 110 volts Single Phase or less for quarter-turn and 415V three phase for
multi-turn.

p)

Certain valve actuators will require fail safe operation in the event of an electricity mains failure. The
Contractor may achieve this either by using fail-safe actuators, or by providing standby power
supplies for the affected actuators. There should be no tendency for any actuator to "creep" either
open or closed, both in normal operation or under mains failure conditions.

q)

Anti-condensation heaters for use on 110 volt a.c. shall be provided for all actuator motors.

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00

April. 2003

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Sewerage Directorate
Abu Dhabi Municipality
r)

The actuator motor gearbox shall be of the total enclosed oil bath lubricated type suitable for
operation at any angle and provided with appropriate filling and drain plugs.

s)

A hand wheel shall be provided for manual operation of the valve. This hand wheel shall not
operate during powered actuator movement by reason of a positive means of disconnection from
the motor driven mechanism. The wheel shall be maintained in its engaged position once this is
selected until powered movement takes place when it shall automatically disconnect and "free
wheel". The hand wheel gearing shall be selected to allow valve operation without undue effort i.e.
not exceeding 25 kg.

t)

It shall be possible to secure hand or powered operation by means of padlocking in the selected
mode.

u)

Where necessary to present the actuator hand wheel at a convenient operating height, flange
mounted pillars shall be provided which fully enclose the necessary valve stem extension spindles.
Supplementary support of the extension spindle within its pillar shall be provided for long shafts.

v)

The open/close direction of rotation shall be clearly indicated on the hand wheel.

w)

A visual position indicator shall be provided within the actuator complete with a pointer showing
open/closed and in travel positions, and a sealed potentiometer to transmit continuous remote
position. Where specified in the particular specification, this indicator shall be illuminated.

x)

Electrical and mechanical disconnection of the motor should be possible without draining the
lubricant from the actuator gearcase.

4.2

Pneumatic

a)

Air actuators shall only be used where specified in the particular specification and shall be of the
double acting type and be field interchangeable without the necessity of removal of the valve or
penstock.

b)

Where a pneumatic actuator is used for modulating control it shall be fitted with integral feedback

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Revision

Date

DIVISION 7

SD/GS/M&E/07020

00

April. 2003

Valves, Penstocks & Actuators

Section 07020

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