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ANSVAUIWA 0543.08, A rat Eaton) American Water Works Association The Authoritative Resource on Safe Water® AWWA Standard Hydraulic and Pneumatic Cylinder and Vane-Type Actuators for Valves and Slide Gates [STANDARD Ee | Since 1881 Effective date: Nov. 1, 2009. First edition approved by AWW Board of Directors Jan, 27, 2008, Approved by American National Standards Institute March 27, 2008. 15666 West Quincy Avenue ‘vocaey Denver, 60 80238-3008 ‘Communeations 77800.926,7337 Conferences ev ane. ore Ebiestion an Tang Selence and Technokeey Seetins Copyrighi ® 2008 American Water Works Associaton. AI Rights Reserved, AWWA Standard ‘This documents an Amedcan Water Works Association AWWA) standard. tls nota Soselcaton. AWN standards describe min ‘mum requirements and do not cantan alo he englneericg and administrative information arma contained in specfeation. ‘The AWMA stancords usualy contain options thet must be evalusted by the User ofthe Standard. Un each opine feature fs pected by te user, the product or sorvice Is no uly defied. AMAA publication of standard does not consti endorse: ont of ary product or product tne, cor doos ANA test, carter approve any Produ. The use of AWM stances sent, vohnten, This stander does rot supersede or take peecodence over or alace any apalcable au, eauaton, o codes of ary sovornmentleuthory. ANWA standarés are intone to ropresent a consonsus ofthe water SUBDY industry that he oduct de- ‘scribd wl provi satisfactory service, When AWWA revises or withdraws this standrd, an ofa naive faction wil be placed lon the first page ofthe lasted advertising section ot ournal AWWA. The action bosoms efectveon the Tre da af the month following the month of uma MW puDtoaton ofthe afl nate American National Standard An American National Standard implies 2 consensus of those eubstantiay concerned wi ks e20pe and provisions An American National Standea 6 Intended as '9 guido to ald the manufecturer, ta consumer, and the genetal puble, Tho exstenee of an ‘american National Standard does tn any respect preclase anyone, nether that person has approved the standard or no, Koh ‘manufacturing, marketing purchasing, o using products, processes, or procedures rt cntonnin tothe standora. AMeean Na tional Standards ave subject to peo eve, and users are eatoned to ablah the lates edtons, Produces o goods made In conformity with an American National Stands are encouged to state Otel om respons In adversing and peomotonal ‘materia or on tags o labels that he goods are produ In confouly wih particular Amerian National Stancards ‘urns Nonee: The American National Standards insite (ANS) approval dato on the font cover f ths standard inletes comple: tion ofthe ANSI approval proves. This American National Stared nay be Fesod or withirain at ary tne, ANS procedures ‘edule that action be taken to rea, esse, or withdraw tv's Standard no later han five yeate om Ih date Of pletion Purchasers of American Naonal Sandals may recehe currant information an al tarards by alg or weing he American Nations! StandarsIstute, 25 West 43rd Sire, Four Foo, Naw York,NY 10036; (212) 642.4900. ‘Alright reserved. No pat of hs pubcallon may be ropredced or ransmited in ary frm or by any mans, eletonic ot ‘mechanical, nculng npotcopy recocing, or ay wormtion oral syst, except nthe frm of Ot exoorps OF ‘hotatons fr review purposes, wiIho the wren parmsaica ofthe pubisher Coppigt © 2009 by American Water Wonks Association Prego in USA CCopycght © 2008 American Wator Werks Association, Al ighls Reeorvad Committee Personnel ‘The AWWA Standards subcommittee on Hydraulic and Pneumatic Actuators, which reviewed and approved this standard, had the following personnel atthe time of approval: Mike Ford, Chair JN. Ballun, Val-Matie Valve 8¢ Manuficturi BAB, Bosscrman, Engineering Consultant, Mission Vigjo, Cal TM. Curry, Laurel, Md, M, Ford, Kinetrol USA Inc., Wakefield, RL AM. Libke, DeZURIK Water Controls, Sartell, Minn, WH. Peflley, Crawford Murphy & Tilly, Springfield, Tl, SS. Richardson, Kinetiol USA Ine., Chaska, Minn. FJ. Washburn, Rotorle Controls Ine., Rochester, NY. Corporation, Elmhurst, Il (AWWA) (AWWA) (AWWA) (AWWA) (AWWA) (AWWA) (AWWA) (awWa) ‘The AWWA Standards Committee on Power Actuating Devices for Valves and Slide Gates, which reviewed and approved this standard, had the following personnel at the time of approval: Fred L. Hinkes, Chair Ammzad Ali, Vice-Chair General Interest Members G.A, Aldworth, Aldworth Engincering Inc. Toronto, Ont. B.E, Bosscrman, Engineering Consultane, Mission Viejo, Calif. ELL. Hinker, Consulting Engineer, Santa Rosa, N.M. ‘TJ. McCandless* Standards Engineer Liaison, AWWA, Denver, Colo. CL. McLain, Standards Council Liaison, Moorhead Public Service, Moorhead, Minn. JP. Masich, WrightPierce, Topsham, Maine WH. Pefiley, Crawford Murphy & Tilly, Springfield, I Producer Members R. Amnold, Rotork Controls Inc., Rochester, N.Y. JV. Ballun, Val-Matic Valve & Manufacturing Corporation, Elmhurst, Il PE, Brunelle, Rodney Hunt Company, Orange, Mass. LH. Elliott, EIM Company Inc, Valve Controls, Missouri City, Texas * Liaison, nosvoting Wi Copyright © 2009 American Watee Works Assocation. Al Right Reserved (AWWA) (Awa) (AWWA) (AWWA) (awa) (NEWwa) (Awa) (Miss) (AWWA) (awwa) (vMa) R.D. Oaks, AUMA Accustors Inc, Canonsburg, Pa. awa) M.D, Rooney.* Lynchburg, Va. awwa) User Members A. All, Greater Vancouver Water Disteiet, Burnaby, B.C. cawwa) TM, Curry, Laurel, Md. cawwa) “EW, Knowlton, Salem 8& Beverly Water Supply Board, Beverly, Mas. (NEWWA) DM. Reidy, Veolia Water, Indianapolis, Ind. (awwa) D.C. Stone, Denver Water Department, Denver, Colo, (awwa) * Alternate Copyright© 2009 American Water Works Associaton. Al Rights Reseed. Contents AMLAWTWA standards follow the general format indicated subsequently. Some variations from this format may be found in a particular standard. see. ed Foreword I Introduction 7 vii LA Background, vii 1B History, vii LE Acceptance. vii TT Special Issues. vii ILA Discussion ILB Hydraulic Fluid.. I Use of This Standard.. sos Vi TILA Purchaser Options and Alternatives IILB Modification of Standard. x IV Major Revision: seven Hh Vo Comments nnn xi Standard 1 General LI Scope. 1 12 Purpose 1.3 Application. 2 3 3 4 Requirements 4.1 Materials. 4.2. Data to Be Furnished by Actuator Manufacturer 43 Actuator ste, ace 44 Cylinder and Vane-Type Actuators— General Ds 8 4.3 Hydraulic/Pneumatic Actuator Applicationsnninnsns 15 46 inting and Coatings wasn 18 5 Verification 5.1 General .... » 18 5.2 Proof-of-Design Tests . 18 5.3 Performance Tests. 5A Test Certification. 21 5.5 Inspection and Testin; - 21 6 Delivery 6.1 Markin . 2 62 Packaging, Shipping, and Storage. 22 63 Affidavit of Compliance... Appendix A ANSI/AWWA C541-08 Pneumatic or Hydraulic Actuator Data Baraat esse eeeeeeseeesee 2g) Figure 1 Types of Actuators and Cylinders Described in This Standard... 2 Table 1 Prototype Actuator Test Cycles Required . 20) CCopyigh® 2009 American Weter Werks Assocation. Al Rights Reserved This page intentionally blank. Copyright © 2009 American Wiser Works Asscclation. Al Rights Reserved, Foreword “This foreword is for information only and is not a part of ANSUAWWA C541 1. Introduction. LA. Background ‘This standard describes hydraulic and pneumatic cylinder- and vane-type-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 cover pilot and control apparatus used to actuate the operating device. LB. History ‘The first edition of the ANSI/AWWA C540 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 commitree was formed by AWWA in 1974 and charged with the development of standards on prime movers for valves and sluice gates, including clectric motors and cylinders employing ain, water, and oil. The second edition of the ANSI/AWWA C540 standard was approved by the ANWA Board of Directors on June 6, 1993, and added quarter-turn actuators. The third edition was approved on June 16, 2002. It added vane-type actuators and digital controls, In 2004, the original single standard was split by the Standards Council into ewo separate standards, one for electric motor-actuated devices (C542) and this one (C541) for hydraulic and pneumatic cylinder and yane-type actuators. These two standards replace the ANSUAWWA C540 standard. This frst edition of ANSU/ AWWA C541 was approved on January 27, 2008 LLC. Acceptance. NSP/ANSI 60 Drinking Water Chemicals—Health Effects, and NSF/ANSI 61, Drinking Water System Components—Health Effects are not applicable to this standard. TI. Special Issues. ILA. Diseussion, At the time this standard was approved, existing AWWA. standards reference ANSIVAWWA C540 rather than include the new separate power- actuator standards, ANSU/AWWA C542, Blectric Motor Actuated Devices for Valves and Slide Gates, and ANSUAWWA C541, Hydraulic and Pneumatic Cylinders and ‘Vane“Type Actuators for Valves and Slide Gates. ANSI/AWWA C541 describes only the design and performance of those actuating devices applied to systems with operating pressures normally encountered in water utilities, Purchasers of hydraulic and pneumatic eylinder- and vane-type-actuating devices should carefully review the requirements of this standard, evaluate the (Copysight © 2008 American Wator Works Associaton, Al Rights Reserved, information to be provided to the manufacturer, and review the data to be supplied by the manufacturer, Such evaluations are essential co ensure proper application of hydraulic and pneumatic eylinder and vane-type actuated device for the intended use. Specific requirements for controls and accessories and other items not described in this standard must be included in the purchase documents. ILB. 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, i is essential thatthe hydraulic fluid notimparc any taste ‘or odor of 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 watee back into the potable system. Ill. Use of his Standard. Ic is the responsibility of the user of an AWWA standard to determine that the products described in that standard are suitable for use in the particular application being considered. “This standard includes certain options that must be selected and specified by the purchaser to completely describeand obtain che actuator desired. In addition to chefactors in Sec. ILA, Purchaser Options and Alternatives, other factors to be considered when sizing an actuator ate described in Sec. 4.3, Actuator Sizing, The following summarizes the options that must be selected and the data that should be covered in the purchase documents covering actuators manufactured in accordance with this standard: TULA. Purchaser Options and Alternative, ‘The following items should be provided or requested by the purchaser: 1. Standard used—that is, ANSI/AWWA C541, Hydraulic and Pneumatic Cylinder and Vane-Type Actuators for Valves and Slide Gates, of latest revision, 2. Specific actuator and equipment data. a. Data Form Sheet (appendix A). This standard allows the use of galvanized tie rods (Sec., 44.5.8, and Blectrogalvanizing is allowed. Users should be aware that clectrogalvanizing offers limited cor- rosion protection. If corrosion resistance is a concern, then the user should require stainless-steel rods, b. Driver medium—air, water, or oil (Sec., c. Driver-medium properties if differing from those in Sec. d. Mi valve or slide gate is to be operated (Sec. 4.5.3). €. IF required, adjustable flow-control devices and opeaing and clos- ing speeds if other than specified (Sec. 4.5.2). tum and maximum pressure of driver medium when the vit ‘Copyrigh © 2009 American Wate Works Associaton. Al Right Resorvad £. Need for special auxiliaries, such as fail-safe, spring-return pneu- matic or mechanical override. Controls and special devices, such as solenoid valves, additional speed-control valves, manually operated valves, interconnecting piping, limit switches, and positioners. h. Voltage available for solenoid valves. i, Control signal available for positioners, j. Special communication protocol. Kk, Major design features (Sec. 4.4.3, Sec. 4.4.4, Sec. 4.4.5, See. 4.4.6, and Sec. 4.4.8). 1. Pneumatic actuator prelubrication (Sec, ‘m, Data by supplier: On request by the purchaser, the supplier should provide the following: 1) Certification of nonmerallic-cylinder-material confirmation tests (Sec. 2) Cer 3) Certification of performance tes (See. 5.3). 4) Affidavit of compliance (Sec. 6.3). 5) Drawings and manuals (Sec. 4.2). ification of proof-of-design test (Sec. 5.2). 3. 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. cc. Rising stem, nontising stem, or quarter turn. Lead, pitch thread, orientation, or keyway dimensions, Direction of rotation of actuator handwiieel to open valve or slide ee gate if other chan counterclockwise (See. £ Weight of gate and stem for slide gate, 8 Seating/unseating torque in foot-pounds (newton-meters), maxi- mum dynamic torque in foot-pounds (newton-metess) and, when appli- cable, thrust in pounds (newrons). h. Maximum torque/thrust capability of che valve or slide gate. i. Minimum hydraulic or pneumatic pressure available for sizing actuator (Sec. j. Failure mode on loss of power: fail open, fail close, or fail in last position on loss of air or hydraulic pressure, control signal, or both, 4. Operating requirements. x ‘Copyright © 2008 American Water Works Azcacntion, Al Rights Reserved a. Type of service a cycle. 2 ‘Open-close. Give frequency of operation and travel time duty ‘Throcling/Modulating. Give operation conditions and input signal to actuator. b. Operating-cycle requirements. ‘Travel time in inches (lineas) ot degrees (rotary) per second (or minute) from fully open to fully closed posi- tions and filly closed to fully open positions under operating conditions. Nore: Unless otherwise specified by the purchaser, actuators will be provid- ed with adjustable opening and closing times between 30 and 60 seconds. ¢ Maximum unbalanced heads or differential pressures against which the valve or gate must open ot close, and maximum pipeline pressure. 4. Ambient temperature and humidity ranges. ¢. Installation location: outdoors, indoors ina 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. 5. Mounting and options 4. Actuator orientation in relation to valve or slide gate b. Type of actuator (See. 4.4). i 2) 3) 4) 5) 9 Oil eylinder per Sec. 44.3. Water cylinder per Sec. 4.4. Pneumatic eylinder per Sec. 4.4.5. Nonmetallic cylinder per Sec. 4.4.6. Quarter-urn actuator per Sec. 4.4.8. Vane actuator per Sec. 4.4.8 © Actuator mounting: directly mounted or remotely mounted on a floorstand and coupled with extension shafting. d. Special coating system (Sec. 4.6). can agen of the purchaser is to vist the plant (Sec. 5.5). £ Special shipping cequirements (Sec. 6). IILB. Modification to Standard. Any modification ofthe provisions, definitions, ‘or terminology in this standard must be provided in the purchase documents. Copyright© 2008 American Wator Works Aseodiatlon, Al Righls Reeerve. IV. Major Revisions, This the first edition of this standard V. Comments. If you have any comments or questions about this standard, please call the AWWA Volunteer and ‘Technical Support Group at 303.794.7711, FAX at 303.795.7603, write to the group at 6666 West Quincy Avenue, Denver, CO 80235-3098, or e-mail, x Copyright © 2008 American Water Works Assocation. All Rights Reserved ‘This page intentionally blank. Copyright © 2009 American Water Werks Atscclatin, Al Right Reserved ANS/AWWA C541-08 é (First Euition) American Water Works Association AWWA Standard Hydraulic and Pneumatic Cylinder and Vane-Type Actuators for Valves and Slide Gates SECTION 1: GENERAL Sec. 11 Scope ‘This standard describes hydraulic and pneumatic eylinder and vane-type actuators for operation of valve and slide gates in utility systems. LL Actuator types. Actuators described in this standard are divided into the following types (Figure 1.1): 1, Gylinder type producing a linear motion, 2. Quarter-um cylinder type producing a rotary motion, 3. Quartertum vane-type actuator producing a rotary motion. 11.2 Actuator function. Actuators shall produce a sorary or linear motion to actuate a valve or slide gate in open—close, throttling, or modulating service. 11.3 Beeluded actuators. ‘he following types of actuators are not included in this standard: 1, Electric motor actuators, 11.4 Other exclusions. ‘This standard does not inchude the following: 1, Piping, controls, and positioners for cylinder actuators, 2. The mechanism connecting a cylinder actuator to a valve or slide gate 4 CCopyaght © 2008 American Water Werks Association. Al Rights Reserve, 2 AWWA C54L.08 Typas of Actuators Typos of Cylinders epee Tires GjlnderAdbaior Ben 84.3 ‘See aa Wisorryarasie ‘See ta Prema Sea44s [Roary Cynder Actor Seca Noneotaie Water Hyrule ond Pravmate ‘see see Fry vine Asaioe Poaumate Vane Bee 448 ‘Seo 4a Figure 1 Types of actuators and cylinders descrtbed in this standard Sec.1.2 Purpose ‘The purpose ofthis standard is to define the minimum requirements for hydrate licand pneumatic cylinder-and vane-type-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 the purchase documents for hydraulic, pneumatic eylinder, and vane-type-actuating devices for valves and slide gates. The stipulations of this standard apply when this document has been referenced and then only to such actuating devices for valves and slide gates. SECTION 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" B93.10M—Static Pressure Rating Methods of Square Head Fluid Power Cylinders ASTMt A36—Standard Specification for Carbon Structural Steel ASTM A48—Standard Specification for Gray Iron Castings. ~ American National Standards Insitute, 25 West 43nd Street, Foutth Flo, New York, NY 10036. 1 ASTM International, 100 Bare Harbor Drive, West Conshohocken, PA 19428, (Copyright © 2009 American Water Works Assocation All Righis Resarved, HYDRAULIC AND PNEUMATIC CYLINDER AND VANE-TYPE ACTUATORS 3 ASTM Al08—Standard Specification for Stec! Bar, Carbon and Alloy, Cold-Finished. ASTM A126—Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings. ASTM A216—Standard Specification for Steel Castings, Carbon, Suitable for Fusion Welding, for High-Temperature Service, ASTM A276—Standard Specification for Stainless Steel Bars and Shapes. ASTM A351—Standard Specification for Castings, Austenitic, Austenit Ferritic (Duplea), for Pressure-Containing Parts. ASTM A395—Standard Specification for Fertitic Ductile Iron Pressure- ng Castings for Use at Elevated ‘Temperatures. ASTM A436—Standard Specification for Austenitic Gray Iron Castings. ASTM A439—Standard Specification for Austenitic Ductile Iron Castings. ASTM. A516—Standard Specification for Pressure Vessel Plates, Carbon Stee, for Moderate- and Lower-Temperature Service. ASTM A536—Standard Specification for Ductile Iron Castings. ASTM AS64/A564M-04—Standard Specification for Hot Rolled and Cold- Finished Age-Hardening Stainless Stee! Bars and Shapes. ASTM A743—Standard Specification for Castings, Iron-Chromium, Iron-Chromium-Nickel, Corrosion-Resistant, for General Application. ASTM B85—Standard Specification for Alumiqum Alloy Die Castings. ASTM BII7—Standard Practice for Operating Salt Spray (Fog) Apparatus. ASTM(B127—Standard Specification for Nickel-Copper Alloy (UNS 04400) Plate, Sheet, and Strip. ASTM B154—Standard Test Method for Mercurous Nitrate Test for Cop- per and Copper Alloys. ASTM B164—Scandard Specification for Nickel-Copper Alloy Rod, Bar, and Wire, ASTM BI79—Standard Specification for Aluminum Alloys in Ingot and ‘Molten Forms for Castings from All Casting Processes, ASTM B240—Standard Specification for Zinc and Zine-Aluminum (ZA) Alloys ia Ingot Form for Foundry and Die Castings ASTM B733—Standard Specification for Aucocatalytic (Blectroless) Nickel- Phosphorous Coatings on Metal. ASTM D570—Standard Test Method for Water Absorption of Plastics. Retais Copyright© 2009 American Water Works Assocation. All Rights Reserved, 4 AWWACB4108 ILZRO* 16—Creep Resistant Zine Die Casting Alloy. NEPA'/T2.6.1—Fluid Power Components—Method for Verifying the Fatigue and Establishing the Burst Pressure Ratings of the Pressure Containing, Envelope of 2 Metal Fluid Power Component, NEPA/T3.47—Accumulator—Pressure Rating Supplement to NEPA/ 72.6.1 R2-2000, Fluid Power Components—Method for Verifying the Fatigue and Establishing the Burst Pressure Ratings of the Pressure Containing Envelope of a Metal Fluid Power Accumulator NFPA/T3.6.8—Fluid Power Systems, Cylinders Dimensions for Accessories for Catalogued Square Head Industrial Types. 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 slide gate or valve closure member, 2. Actuator manufacturer: “The party that manufactures hydraulic, pneumatic, and vane-type actuator devices. 3. Corrosion-ressant metal: Contosion-resistant- metals. shall be stainless steel, nickel-copper alloy, or bronzs, conforming to the requirements of Sec. 4.4.2. 4. Gjele: A erm for the operation ofa valve, actuator, or valve assem- bly describing the movement from the closed position to the open position back to the closed position, or reverse. 5. Glinderactuasor: A uid-powered actuator that uses hydraulic or pneumatic pressure within a cylinder to restrain or move a valve closure member. Air or fluid pressure acts on a piston to provide thrust in a linear motion for gate and globe valves. The thrust is mechanically converted to rotary motion for quarter- turn valves using a link and lever, rack and pinion, or seotch yoke mechanism, 6. Dayz A day's defined as a 24-br period. 7. Duty ele: The cycle of operation fully open to fully closed, oz starts per hour, or eversals per houe thac the actuator is required co perform during * International Lead Zine Research Organization Inc, 2525 Mevidian Paskvway, Suive 100, Durham, NC 2708. 4 National Fluid Power Association, 3383 North Mayfair Road, Suite 211, Milwaukee, WI 53222, Copyright @ 2000 American Water Works Association, Al Rights Reserved HYDRAULIC AND PNEUMATIC CYLINDER AND VANE-TYPE ACTUATORS 5 4 defined period or periods. 8. Manufecturer: The party that manufactures, fabricates, or pro- duces materials or products. 9, Modulating: Operation characterized by the continuous position- ing of a valve or slide gate, between fully open and fully closed, in response to a continuous control signal, 10. Openclese: To move a valve or slide gate to the fully open or fully closed position in one continuous operation. LL. Operating pressure: The minimum and maximum hydraulic or pneumatic pressures, at specified operating temperatures, that an end user provides to operate an actuator. Usually the lowest possible minimum operating pressure available at the point of use is used for sizing actuators. Operating pressure is also referred to as supply pressure ot working pressure. 12. Operating pressure rating: “The minimum and maximum hydrau- ic or pneumatic pressures, at specified operating temperatures, that an actuator or cylinder manufacturer specifies to safely operate their products for optimaurn life. 13. Poweractuated device: A device that uses hydraulic or pneumatic pressure to open, close, or position a valve or slide gate. 14. Pressure rating: The maximum pressure that a manufacturer assigns to an actuator, cylinder, or components that it can sustain without causing a catastrophic failure. 15. 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 che party that will own and operate the actuator after installation. 16. Required actuator torgue or thrust: "The torque ot thrust the actuator must develop to restrain, move, or properly seat a valve or slide gate under design conditions. 17. Safety factor: The ratio between an actual property of a compo- nent to that required under design conditions to minimize risk and to provide for unknown or unforeseen events that can adversely affect service life 18. Seating torque: “The maximum torque required 10 fully seat or unseat a valve or gate closure member, as supplied by the customer or valve manu- facturer, 19. Supplier: “The party that supplies material or services. A supplier may or may not be the valve or slide gate manufacturer ot actuator manufacturer Copyright ©2009 American Wiater Wor Association, Al Rghls Reserve. 6 AWWACS41.08 20. Throttling: Operation characterized by the deliberate ot the infrequent movement of a valve or slide gate to an intermediate position, between fully open and fully closed, and maintaining that position for periods of time, in response to a manually initiated control or a continuous control signal (when a process variable has extended outside a preset dead-band range), for the purpose of changing head loss and regulating flow through a valve or slide gate. 21. Thrust: A linear force on the stem of a valve o: slide gate, gener- ally expressed in units of pounds (newtons). 22. Torque: A rotary twist or turning moment on the valve stem or shaft expressed in units of foot-pounds (newton-meter) 23. Vane actuator: A pneumatic actuator that produces rotary torque by design. SECTION 4: REQUIREMENTS Sec. 4.1 Materials Materials shall comply with the requirements of the Safe Drinking Water ‘Act and other federal regulations for potable water and wastewater systems as applicable. Legislation is subject to change. Therefore, it is the manufacturer's and purchasers responsibility to verify the current requirements of federal regulations. Sec. 4.2 Data to Be Furnished by Actuator Manufacturer 4.2.1 Drawings. When required, the supplier shall submit certified draw- ings to the purchaser for review. Drawings shall show the following: 4, interfacing with the valve or slide gate, general construction, and outline of the 1 Dimensions. Principal dimensions, inchiding those necessary for actuator mechanism. 4.2.12 Wiring diagrams, Electrical wiring diagrams with list of symbols in accordance with ANSI standards, 4.213. Cylinder actuators. For cylinder actuators, the driver medium, pressure racing, bore diameter, rod diameter, and stroke length for linear actuators. 4.2.14 Actuator options. The actuator options being supplied. 4.2.2 Recommended storage practice. This information shall be placed on the outside of the unit or shipping container as delivered to the jobsite or to the purchaser by the supplies. Copyright @ 2009 American Water Works Assocation, Al Rights Reserved, HYDRAULIC AND PNEUMATIC CYLINDER AND VANE-TYPE ACTUATORS 7 4.2.3 Installation, operation, and maintenance manuals. When required, the supplier shall submit manuals containing the following information to the purchaser: Instructions. Complete installation, operation, and maintenance instructions. Partslist. Complete parts list. Spare parts. List of recommended spare parts. 42.34 Special tools. List of sp: or adjustment. ‘wols for installation, maintenanc: 4.2.35 Lubrication guide. Lubrication guide with lis of proper lubricanes, 42.3.6 Certified drawings. One copy of each certified drawing. 424. Marerials lies. When required, a list of materials used in the actua- ‘or shall be supplied. 425 Submittal copies. “The number of cectified drawings, installation instructions, and operation and maintenance manuals specified by the purchaser shall be submizted by the supplier. Sec. 4.3 Actuator Sizing 43.1 Actuator sizing considerations 431.1 Data. When valves or slide gates are to be pneumatically or hydraulically actuated, the purchaser shall transmit the actuator sizing data, such. ot hydraulic supply pressure, mounting, and space considerations to the supplier for actuator sizing, ‘When an existing valve or slide gate is to he actuated by air or hydraulic as required actuator torque or thrust, shafe diameter, available pressure, the purchaser shall transmit the supply pressure, mounting, and space consideration data to the supplier. 43.1.2 Conditions, The correct determination of torque or thrust depends on the purchase documents identifying 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, 43.1.3. Torque requirements, It is necessary to know the following to ensure proper sizing of an actuator to a valve: 1. The maximum seating and unseating torque or thrust of the valve, including factor of safety 2. ‘The maximum running or dynamic torque or thrust of the valve Conyight@ 2009 American Water Werks Associaton, All RightsReserved 8 AWWAC541.08 over the full eyele. 3. The minimum driver medium pressure at the time of actuation. 43.2. Maximum torque or thrust, The stall torque ot maximum thrust ‘output of che actuator shall not exceed the torque or thrust capability of the valve gate, as determined by the valve or slide gate manufacturer Sec.4.4 Cylinder and Vane-Type Actuators—General Design 44. General, Actuator designs and matetial selection shall be compatible with the driver medium and operating pressures to which the actuator will be exposed. The following chree categories of actuator operating pressures and media are described in this standard: (1) oil-hydraulic actuator operating up to 2,500 psi (172 MPa) oil working pressure, (2) pneumatic actuator operating up to 150 psi (1.03 MP2) air pressure, and (3) water-hydraulic actuator operating up to 150 psi (1.03 MPa) water pressure. Hydraulic oil may also be used in water-hyraulic actuators up £0 150 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. or sli 44.2 Materials, Materials designated herein, when used in actuators pro- dduced according to the provisions of this standard, shall conform, at a minimum, to the requirements designated in Sec. for each material listed. When refer- ence 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. 442.1 Physical and chemical properties. Materials shalt be in confor ‘mance with the physical and chemical requirements of this subsection as follows: 1. Alloy cast iron. ASTM A436 type 1 or type 2, or ASTM A439 type D2. 2. Aluminum, ASTM B179, Alloy 356.1 (UNS A03561), 3. Aluminum. ASTM B85. 4, Brass or bronze, Components of brass or bronze shall be made to ASTM 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 B1S4 to minimize susceptibility to stress corrosion, Because of dezincification consider- ations, bronze parts subject to warer contact shall contain not more than 7 percent inc. Aluminumbronze parts subject to water contact shall be inhibited against dealuminization by receiving a temper anneal at 1,200°F (650°C) + 50°F (28°C) for 1 hrfin, (25.4 mm) of section thickness followed by cooli water quenching, in moving air or by Copyrigt © 2008 American Water Works Assocation. Al Rights Reserved HYDRAULIC AND PNEUMATIC CYLINDER AND VANE-TYPE ACTUATORS 9 5. Castiron. ASTM A126 class B or ASTM A48 class 40, minimum, 6. Cast steel, ASTM A216 grade WCB. 7. Carbon steel. ASTM A108. 8. Ductile iron, ASTM A536 grade 65-45-12 or 60-40-18 or 80-55-06, or ASTM A395 grade 60-40-18. 9. Electroless-nickel plate. ASTM B733, ‘Thickness class SC3 (0.001 in}, is recommended for moderate environments such as nonmarine out- door exposure, alkali salts at elevated temperature, and moderate wear. 10. Fabricated steel. ASTM A36, ASTM ASI6, Il. Nickel-copper alloy. ASTM B127 or ASTM B164. 12, 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, or ASTM A564, Type 630. 13. Zinc Alloy. ASTM B-240 or ILZRO 16. 443. Oithydraulic cylinders, Oit-hydraulic eylinders shall be of tie-r0d, bolted-Hange, or welded construction and suitable for operating pressures up t@ a maximum of 2,500 psi (17.2 MPa). (68.9 MPa). ‘The purchaser shall select appropriate oil-hydraulic cylinders of ie-tod, imum burst pressures shall be 10,000 psi bolted-fange, or welded construction, according to the rated operating oil pressure of che system designed. Cylinder mounting dimensions shall comply with applicable requirements of NEPA/T3.6.8 regarding mountings and physical dimensions with modifications where required to adapt to the valve or slide gate actuator's ¢ mounting. Cylinder pressure ratings shall be determined per ANSI B93.10M. The hydraulic cylinders shall be those catalogued by power-cylinder manufacturers certifying that the selected eylinders comply with the above ANSI and NEPA standards, with modifications noted. No special corrosion-protection coatings or corrosion-resistant materials shall be required unless specified by the purchaser. Corrosion-resstant materials, if required, shall be corrosion-resistant metal or nonmetallic material, 443A Seals, Static and dynamic seals shall be pressure energized and shall be compatible with the hydraulic Buid to be used. 443.2 Component suitability. Descsiptions of components for oil- hydraulic cylinders arc not listed in detail in Sec. cylinders may choose to consider materials in Sec, 4.4.2 and provide requirements 3, Purchasers of oibhydraul ‘on individual components of oil-hydraulic eylinders, Copyright© 2009 American Weter Works Assocation. Al Right Reserved 10 AWWAC541-08 4433 Cylinder barrels. Cylinders shall be made from a suitable car- bon steel material that can operate under the pressure guidelines as outlined in Sec. 443, 4434 Head and caps. Head and caps shall be carbon steel 4435 Cylinder piston. Cylinder piston shall be of a suitable carbon- steel material. 4436 Piston rod. Piston rod shall be stress-proof steel and clectroless- nickel or hard-chrome plated. Electroless-nickel or hard-chrome plating shall be a minimum of 0.0005 in. (0.0127 mm) thick and have a 20-mictoinch (0.508 pm) finish or smoother. 44.37 Internal fasteners. Internal fasteners shall be of a suitable carbon- steel material. 444A Water-bydraulic cylinders. Water-hydraulic cylinders shall be of external tie-rod or bolted-flange construction and shall have a pressure rating of 150 psi (1.03 MPa) minimum, as determined by ANSI B93.10M. Cylinder mount- ing dimensions shall comply with NEPA/T3.6.8 regarding mounting and physical dimensions with modifications where required to adapt to the valve or slide gate actuator's cylinder mounting. Construction materials shall be selected to ensure adequate corrosion resistance with a design safety factor of 4:1 based on tensile strength. 444.1 Cylinder barrels, Cylinder barrels shall be bronze, fiberglass- reinforced plastic, or stainless-steel or carbon-stee electroless-nickel or hard-chrome plated. Blectroless-nickel or hard-chrome plating shall be a minimum of 0.0005 in. (0.0127 men) thick. “The inside barrel shall have 2 20-microinch (0.508-pm) finish ‘or smoother. 444.2 Heads and caps, Heads and caps shall be bronze, suitable non- metallic material, ductile iron, or steel. Steel or ductile-iron components shal have plated surfaces. ‘The plating shall withstand a saltspray test of not less than 144 hr in accordance with ASTM BLI7. 4443 Cylinder pistons. Pistons shall be bronze, suitable nonmetallic material, stainless steel, cast iron, ductile iron, or stel. 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 BII7. Cylinder pistons shall not come in contact with the cylinder batrel. This can be accomplished by the use of nonmetallic wear strips or integcal body support of the piston rod. Copyright 2008 American Water Works Assocation. Al Rights Reserved, HYDRAULIC AND PNEUMATIC CYLINDER AND VANETYPE ACTUATORS 14 4444 Piston rod. Piston rods shall be 30,000-psi (206.8-MP2) mini: mum yield strength, stainless-steel hard-chrome or electroless-nickel plated. Hard- chrome plating or electroless-nickel plating shall be a minimum of 0.0005 in, (0.0127 mm) thick and shall have a 20-microinch (0.508-um) finish or smoother, 4445 Piston-tod bushing. Bushings shall be bronze or nonmetal- lic materials suitable for water service and having a beating capacity of 1,500 pst (10.3 MPa) minimum. 444.6 Rod seals. Seals shall be nonmetallic elastomeric materials suit- able for water service, Rod seals shall be of a pressure-energized design. 4447 Piston seals, Seals shall be nonmetallic elastomeric materials sui able for water service. Piston seals shall be of a pressure-energized design. 444.8 Tie tods. Rods shall be carbon or stainless steel, cold rolled, with ‘a minimum yield strength of 60,000 psi (413.7 MP2). 445° Pneumatic cylinders. Pneumatic cylinders shall be of external tie~ tod ot bolted-flange construction with a pressure rating of 150 psi (1.03 MPa) min- imum, Cylinder mounting dimensions shall comply with applicable requirements ‘of NFPA T.3.4,7 regarding mountings and physical dimensions with slight modi cations where required to adapt to the valve or slide gate actuator’s cylinder mount- ing. Cylinder pressure ratings shall be determined per ANSI B93.10M. However, ANSI/AWWA C541 is not restricted to such a cylinder category provided the fol- Jowing macerials are used with an adequate design safety Factor of 4:1 445.1 Cylinder barrels. Barrels shall be bronze, fiberglass-teinforced plastic, carbon steel, stainless steel, or hard-drawn brass. The inside surface of the barrel shall have 2 20-microinch (0.508-ym) finish or smoother. If carbon- steel material is used, the inner surface shall be hard-chrome plated 0.0008 in. (0.0127 mm) thick or electroless-nickel plated to the same thickness. 445.2 Heads and caps. Heads and caps shall be carbon steel, suitable nonmetallic material, or ductile iron. Surfaces, except nonmetallic material, shall be chrome- or cadmium-plated, clectroless-nickel plated (END), or have a baked- ‘on epoxy coating if specified by the purchaser. 4453. Cylinder pistons. Pistons shall be stainless steel, carbon steel, suitable nonmetallic material, cast iron, or ductile iron. Carbon-stecl castiron, ‘or ductileciton surfaces shall be chrome- or cadmiumeplated if specified by the purchaser. Metallic pistons shall not be used with nonmetallic cyl unless nonmetallic wear strips are provided or the actuator housing design provides integral piston rod support. Copyright @ 2009 American Water Works Assoclatlon. Al Righs Reserved 12 AWWACS41.08 4454 Piston rod. Piston rods shall be 30,000 psi (206.8 MPa} mini- mumeyield-surength carbon steel or stainless steel. Boch materials shall be hard- chrome or electroles-nickel plated, Hard-chrome plating or clectroless-nickel plat- ing shall be a minirwum of 0.0005 in, (0.0127 mm) thick and have a 20-microinch (0.508-1m) finish or smoother. 4455. Piston-rod bushing. Piston-rod bushings shall be iron, bronze, or a nonmetallic material suitable for air sevice. 445.6 Rod seals. Rod seals shall be elastomeric materials suitable for service and designed to be pressure energized, 445.7 Pistonsseals. Piston seals shall be elastomeric materials suitable for air service. Piston seals shall be of a pressure-energized type. 445.8 Tie rods, Tie rods shall be carbon or stainless steel, cold rolled, with a minimum yield strength of 60,000 psi 413.7 MPa). 446 Nonmetallic water-bydraulic and pneumatic cylinders. Nonmetallic wwater-hydraulic and pneumatic cylinders shall be of tie-rod construction and shall have a pressure rating of 150 psig (1.03 MPa) minimum. Construction materials shall be selected primarily on the basis of cocrosion 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 che 150-psig (1.03-MPa) pressure rating. Furthermore, materials selected shall have a maximum, ‘water absorption of 2 percent after 24 hr in a Yuin, (3-mm) thick section when tested per ASTM D570. 44.61 Cylinder barrels. Cylinder barrels shall be fiberglass-reinforced plastic or glass-fber-einforced epoxy-resin tubing having an inside surface finish ‘of 20 microinches (0.508-pm) or smoother. No fiberglass strands shall extend to the inside surface. 4462. Heads and caps. Heads and caps shall be molded or machined from thermoplastic, thermoset, laminated phenolic materials or cadmium-plated ductile iron. Fixed-mounted cylinders shall be attached to the valve or slide gate operating mechanism by means of plated or corrosion-protected coated-stee! plates {as described in See. 4.6) retained to the cylinder proper by means of the tie rods. Pivot mount cylinders shall be attached to the valve or slide gate operating mecha- nism by means of plated or corrosion-protected coated clevis or trunnion plates retained to the cylinder proper by means of the tie rods. Such metallic plates or levis shall be external to water passages in the cylinder. 4463 Cylinder pistons. Cylinder pistons shall be molded or machined from thermoplastic, thermoset, laminated phenolic materials, or cadmium-plated ductile iron. Particular attention shall be paid to ensure that the materials selected Copyright @ 2000 American Water Warks Associaton. Al Rghls Reserved HYDRAULIC AND PNEUMATIC CYLINDER AND VANETYPE ACTUATORS 43, dlo not have excessive water absorption or lack dimensional stability. 44.64 Piston rods. Piston rods shall be 30,000 psi (206.8 MP2) min- imum yield strength, stainless-steel, or carbon-steel hard-chrome or electroess- nickel plated. Hard-chrome plating or electroless-nickel plating shall be a mini- mum of 0.0005 in. (0.0127 mm) thick, having a 20-microinch (0.508-pm) finish or smoother. Piston-rod bushings. Piston-rod bushings shall be bronze or non- ‘metallic materials suitable for water service and having a high bearing capacity of 1,500 psi (10.3 MPa) minimum. 44.6.6 Rod seals. Rod seals shall be elastomeric materials suitable for ‘water service and designed to be pressure energized. 44.6 Piston seals. Piston seals shall be elastomeric materials suitable for water service. Piston seals shall be of a pressure-energized design. Tie rods. Tic rods shall be cold-rolled, zinc-plated carbon stecl or stainless steel Bither material shall provide a minimum yield strength of 60,000 psi (413.7 MPa). 44.69 Material selection confirmation. Prior to che prooFof-design tests outlined in Sec. 5.2, prototype nonmetallic-material cylinders shall undergo the following additional tests co demonstrate proper material selection. 4469.1 Bacheylinder tobetested 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 eyele. 4469.2 If the same nonmetallic-design cylinders are to be used for both. warer-hydraulic and pneumatic service without any changes, the eylinder shall bbe tested as a pneumatic unit at 150-psi (1.03-MPa) air pressure for 5 minutes. No leakage shall be allowed across the piston in either direction with the piston retained at midstroke. 44.7 Quarter-turn cylinder actuators. For operation of quarter-turn is required to convert a cylinder’ 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 valves, an intermediate mechani that should be reviewed by the purchaser 44.7.1 General requirements, “The actuator shall include a tigid 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, Copyright © 2009 American Water Works Assocation, Al Rghls Reserve, 414 AWWACS4L.08 based on the ultimate strength, or a minimum safety factor of 3, based on the yield stength of materials used. Linkage shall contain an adjustment for sting the valve in the closed position. 44.7.2 Bearings. Moving surfaces shall be supported by antiftiction bear- ings. 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. 445 of lubricane regardless of position, Lubricants shall be suitable for year-round ser Lubrication, Housings shall contain seals to prevent the leakage vice based on prevailing ambient temperature conditions. In addition, the user of this standard must identify if the purchaser or the application requices the lubri- cant 0 be food-grade quality 4474 Handwheel: Optional handwheels shall be so connected that ‘operation by the actuator shall not causc the handwhecl to rotate. Operation of the hhandwheel will assume loss or isolation of hydraulic or pneumatic pressure to the actuator. The handwhedl shall require a maximum input force of 80 Ib (356 N) on the rim for a seating or unseating load. The handwheel shall also require a maximum input force of 60 tb (267 N) on the rim at any point through the travel for the running. load. The handwheel shall have an arrow and the word “OPEN” or “CLOSED” integrally cast or permanently affixed indicating the required direction of rotation. In the event that an optional handwheel isnot. suitable means for manual operation, an optional self-contained oil hydraulic manual overtide may be offered. 4475 Position indication. Position indication shall be accomplished by means of an indicator dial or arrow in full step at all times with valve or slide gate travel during power and manual operation. The indicator dial shall be graded in 25 percent increments at a minimum, that is, quarter open, half open, three quar- ter open, and open. 4476 Stopimiting devices. Valve actuators shall be equipped with adjustable, mechanical, stop-limiting devices to prevent over-travel of che valve in the open and closed positions. 4477 Housing. ‘The actuator housing shal be cther cast ductile iron or fabricated carbon steel in order to maintain correct beating alignment. The hous- ing shall be a fully enclosed design to preclude the possibility of injury to personnel during operation. "The actuator housing shall be capable of being lubricated with cither grease o, ifthe design allows, oil bath lubrication, When a removable cover is provided, the pneumatic actuator body cover shall be easily removable from the Copyright @ 2009 American Water Works Assocation. Al Righs Reserved, HYDRAULIC AND PNEUMATIC CYLINDER AND VANE-TYPE ACTUATORS 15 top of the actuator body to allow for inspection of the center body without disas- sembling the entire unit or removing the unie from the valve 447.8 Yoke. The actuator yoke shall be constructed of high-yield ductile iron or fabricated carbon steel. After machining, all surfaces are to be corrosion protected. The yoke shall have two keyways that are machined ninety degrees apart from one another, which allows the actuator to be easily rotated from one position to another in the field. 4479 Yoke pin. "The interface between the scotch-yoke mechanism and the yoke pin shall be an aluminum bronze slipper that is designed to allow for the force transference of the actuator over a larger surface area. The yoke pin is to be of high-grade steel capable of withstanding the high stresses inherent in a scotch-yoke designed actuator. 44.8 Pneumatic quarter-turn vane-type actuators, Pneumatic quarter turn rotary actuators shall be of the vane-type design wich operating pressure ré ings up to 150 psig (1.03 MPa). 44.8. Actuator housing. Housing shall be of aluminum or zine alloy construction. ‘The interior and exterior surfaces of the housing shall have a fusion- bonded or baked-on epoxy coating. 44.8.2 Vane construction. Vane shall be of stainless steel, zinc-plated iron, or electroless-nickel plated carbon-steel construction. Vane and output shafts shall be of one-piece design. 4483 Actuator output shafts. Actuator output shafts shall include PTEE (polytetrafluoroethylene)-impregnated bronze bushings backed by stecl. 44.84 Vane seals. Vane seals shall be of a material suitable for air, Seal housing contact shall be accomplished by means of 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 ourput shaft. No compressed air or uid shall be allowed at the output shaft. 448.5 Hardware. Stop sctews and case bolts and nuts shall be stainless sceel. Sec.4.5 Hydraulic/Pneumatic Actuator Application 45.1 Operating presures. 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. ‘Actuator sizing shall be based on the minimum driver-medium supply pressure specified by the purchases. CCopyreht © 2008 American Water Works Associaton, Al Rights Resowed. 16 AWWACSAL08 45.2 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 set for a range of 30 sec to 60 sec. All hydraulic actuators shall have provisions to change the operating time using adjustable control valves at or neat each port to vary flow in and out of che actuator. However, the maximum operating time for pneumatic actuators without slave cylinders should be limited to not more than 5 seclin. of stroke to avoid jerky operation. Final adjustments shall be made by the purchaser to minimize line surges during normal operation. 45.3 Actuator requirements. Pneumatic and water-hydraulic actuators shall not require more than 7-psi (48-KPa) pressure to cycle a complete stroke in cach direction before being connected to a valve or slide gate operating mecha- nism. Oil-hydraulic actuators shall not require more than 15 psi (103 kPa) for the same type of cycling. 454 Rod-seal protection, Actuators shall be equipped with externally fac- ing dire wipers to protect the rod seals from dirt and other foreign matevials, The externally facing wiper will nor be required if the rod is fully protected by a sealed boot or a totally enclosed gasketed cover. 45.5 Driver media. 4551 Scope. “This section covers the minimum quality of driver media to be provided by the purchaser for actuators of the pneumatic, water-hydraulic, and oil-hydraulic types for valves and slide gates in open-close, throttling, and modulating service. Driver media includes air for pneumatic actuators, waver for water hydraulic actuators, and oll for oil-hydraulic actuators. 455.2. Properties covered. ‘This standard covers physical, chemical, and temperature/pressure suitability of che driver medium to actuator components and tw 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 clate to corrosion deterioration caused by aggressive chemical, low pH conditions, and excessive dissolved minerals (or example, scaling damage from very high hardness in water medium). Témperature|pressure properties relate to operating problems or material damage caused by excessively high or low temperature or pressure of the medium. 4553 Pneumatic-medium requi Copyright© 2008 Amarican Water Works Assocation. AI Rights Reserved HYDRAULIC AND PNEUMATIC CYLINDER AND VANE-TYPE ACTUATORS 47 4, For open-close service, compressed air shall have dirt and scale particles and water droplets removed to no larger than 40 pm (1.6 mil). Ieis ecom- mended that the purchaser provide air-line lubricators for an open-close actuator unless ocherwise indicated by the actuator manufacturer. For throting or modulating service (with positioner), com- pressed air shall have dirt and scale particles and water droplets removed to n0 larger than 5 ym (0.2 mil). Factory prelubrication of the actuator shall be provided by the actuator manufacturer unless otherwise specified. Ic is recommended that the purchaser provide aic-line filters to remove oil-mist droplets to no larger than 5 ym (0.2 mil) for protection of the positioner. The use of air-line lubricators should be avoided. 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, Compressed air free of harmful chemicals shall be used unless otherwise specified. Nonreactive gas (such as nitrogen) may be used in lieu of com- pressed air ifso specified by the purchaser. 4, Compressed-air temperatures up to 130°F (544°C) and pres- sures up to 150 psi (1.03 MPa) shall be used unless otherwise specified. 4554 Waterhydraulic medium requirements, Hydsaulicwater medium shall have dict and scale particles removed to no larger than 20 jim (0.8 mils). 4.55.42 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.) shall be used unless otherwise specified. For potentially aggressive (low-alkaline) waters, a water analysis that includes total hardness, pH, CO, and conductivity should be made and included in the purchase documents. Hydsaulic-water temperatures up co 125°F (51.6°C) and pres- sures up to 150 psi (1.03 MPa) shall be used unless otherwise specified. 4555 Oilhydraulic medium requirements. The user of this standard ‘must identify ifthe purchaser or the application requires the oil-hydraulic medium to be food-grade quality. Hydraulic oil shall have dirt and scale particles and water droplets removed to no larger than 10 pm. Viscosity of hydraulic oil shall be 135 to 165 SSU (Standard Saybolt Universal) at 100°F (37.8°C) unless otherwise specified. 4555.2 Hydraulic oil shall be used unless otherwise specified. Where Copytigh © 2009 American War Werks Assocation. Al Rights Reserved 18 AWWAC54108 an alternative oil medium is intended, the purchaser should clearly specify ies characteristics, Hydraulic-oil temperatures up to 200°F (93.3°C) and pressures Lup to 2,500 psi (17.2 MPa) shall not be exceeded unless otherwise specified. When hydraulic oil is used with water-hydraulic-type cylinders, pressures of 150 psi (1.03 MPa) and temperatures of 130°F (54.4°C) shall not be exceeded. Sec. 4.6 Painting and Coatings 46.1 General. Actuators shall be shop coated. Coatings for special set= vice shall be as specified by the purchaser. 4.6.2 Internal surféces. 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. 463 External surfaces, External surfaces, except machined surfaces, shall be thoroughly cleaned and shop coated with a suitable primer or paint system to a dry film thickness of not less than 3 mils (76 jim). Machined surfaces shall be coated with suitable rust preventive applied in accordance with the actuator manu facturer's recommendations. SECTION 5: VERIFICATION Sec.5.1 General ‘Two types of tests are required: prook-of-design rests and performance tests. “The purpose of the proof-of design test is to prove that the design, material selec- tion, 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 requite- ments for each type of test. Sec.5.2 Proof-of-Design Tests 5.21 General requirements. One production sample of each 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 fanction, the test shall be repeated. Copyright© 2008 American Watee Werks Associaton. All Righls Raserved HYDRAULIC AND PNEUMATIC CYLINDER AND VANE-TYPE ACTUATORS 19 5.2.2 Linear eylinder actuator. The proof ofdesign test for a hydraulic or pneumatic linear cylinder actuator shall consist of cycle cesting (close-open-close) of a production sample for each model/size actuator at the rated pressure of 5,000 complete cycles. Pressure shall reach rated pressure at the end of each steoke. Fail- ure of any component during the test shall constitute failure of the test. As part of the proofof-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 pres- sure, 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. Test report. Each test report shall include the following at a minimum: Bore size. Stroke. Number of cycles. 4, Pressure. 5. Driver medium. 6. Results of hydrostatic test. 5.23 Quarter-turn cinder aetuator, "The proof of design test for a quar- terturn cylinder actuator shall consist of the requirements of Sec. 5.2.2 for eylin- ders and the following. Test procedure. A production sample of each model actuator shall be given a torque test equal to or greater than twice the rated torque, through ‘one complete open-and-close cycle. The design shall also be verified by cycle test- ing of one production sample of each actuator body size chrough full cycles with full rated torque at the point of unseating and a minimum of 30 percent of the rated torque during the open-and-close stroke. The number of cycles shall be in accordance with Table 1 ‘Test report. Each test report shall include the following at a minimum: Actuator unit size and model. Cylinder bore and stroke tested, Number of cycles. Rated torque. Applied torques. a Results of examination. Copyright © 2008 American Water Works Associaton. All Righls Reserved 20. AWWA.C541-08 Table 1 Prototype actuator test cycles requited “Torque Range fil (Nom) Number of eeles Up 00 3,750 (6,080) 10,000 3.751-6,250 (6,080-8,470) 5,000 6,251 and greater (8.470 or greates) 1,000 524 Quarter-turn vane-type pneumatic actuator. The prookoFdesign test for a Mi turn vane-type pneumatic actuator shall consist of a life eet of a pro- duction sample of each actuator size. The test shall be completed at greater than 90 percent full load torque in both ditections of operation at the maximum recom- ‘mended operating pressure for a minimum of 2 million operations. (An operation is defined as one movement ofthe actuator from one end of the stroke ta the other.) Failure of this tes shall be defined as an inability to produce rated torque, excessive sideways movement of the output shaft (0.008 in, (0.2 mm maximum), excessive wear in the output shaft square drive, or failure of mounting interface. Operating, ambient conditions will be 70°-90°F (21.11°-32.22°C). 5.24.1 Test report. Bach test report shall include che following mini- mum information: 1, Actuator size/model number. 2. Actuator swept volume. 3. Actuator dead volume. 4. Number of cycles. 5. Rated torque 6. Results of examination Sec. 5.3 Performance Tests 5.3. General requirements. Bach actuator shall be performance-tested prior to shipment. Ifany component of the unit fails during testing, the malfunc- tion shall be corrected or repaired as required and the unit retested. 5.3.2 Gylinder actuator, Bach actuator shall be cycled a minimum of three times from the fully closed to che 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 ot 15 psi (103 kPa) for oil-hydraulic cylinders as stipulated in Sec. 45.3. Oil-hydraulic actuators. Each completed actuator assembly shall Copyright® 2009 American Water Works Associaton, Al Rights Reserved, HYDRAULIC AND PNEUMATIC CYLINDER AND VANE-TYPE ACTUATORS 21. be rested atthe rated pressure, pressurizing each port in turn, During the ces there shall be no leakage at the head or cap ends, the rod seals, or ocher static seals. There shall also be no leakage past the piston seals or evidence of detrimental or perma nent deformation of any part. The duration of this test shall be sufficient ro allow visual examination for leakage and shall be atleast 1 min. 53.2.2 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 actoss the piston. The duration of this est shall be sufficient to allow visual examination for leakage and shall be at least 1 min. Pressure shall be applied indi- vidually to the head port and cap port for this test. There shall be no evidence of detrimental or permanent deformation of any patt. Test report. Each test report shall include the following at a Bore size, Stroke. Number of cycles, Pressure. Driver medium, Results of operation and pressure tests, Sec. 5.4 Test Certification Certification of tests and copies of rest reports shall be provided on request. Sec. 5.5 Inspection and Testing ‘Work performed in accordance with this standard shall be subject to inspec~ tion by the purchaser. The purchaser shall have access to 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 actua- tors or parts rejected by the purchaser because of failure to conform to the require- ments of this standard shall be made satisfactory or replaced. If the purchaser is not at the plant, the actuator manufacturer shall certify that the required tests will be made. In this case, no component or actuator shall be furnished thar has not been tested and found to conform to the requirements requested by the of this standard. Copies of the test results shall be provide purchaser. (Copyright © 2000 American Water Works Ascosiation. Al Rights Roeowved, 22. AWWACS41-08 SECTION 6: DELIVERY Sec. 6.1 Sec. 6.2 Marking A stainless-steel or aluminum nameplate or nameplates containing the fol- lowing data shall be permanently mounted on the actuator housing or motor. 1. Manufacturee’s name, 2. Identifying model number and/or serial number. 3. Supply pressure. 4, Maximum supply pressure rating. 5. Cylinder or vane size, Packaging, Shipping, and Storage Actuators, whether shipped assembled on slide gates or valves oF 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 ‘male threads on actuators and controls shall be protected with tape or eaps. Open- ings into actuators or controls shall be closed by means of caps or plugs. Electrical enclosures that are not weathertight by design shall be protected against the ele- ‘ments before and during shipment. Ifactuators 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 actuator. Ifactuators with electrical 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 pre- cautions can be taken. If itis necessary for the purchaser to take any precautions during extended storage, such as 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. Nore: This standard is intended to cover normal domestic shipment (rail, ais, or truck), normal handling (hoists, cranes, or forklifis), 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 ‘The purchaser may require an affidavit from the manufacturer or supplier that the material provided complies with applicable requirements of this standard ‘Copyright © 2009 American Water Works Association All Rights Reserved APPENDIX A SizerType. Rotary, Linear Rotation of Rotary Valve Clockwise to cose Clockwise to open Maximum Required Torque or Thrust / uni Degrees irom close to open __ Travel of Linear Valve (close to oper Valve Stem’Shatt Type & Diameter: Weight of Gate & Stem for Slide Gat Rotary (check one) Linear (check it applicable) Piston Cylinder Piston Cylinder Rack and Pinion ‘Soatch Yoke Vane, Es Driver Medium (check ene): Pneumatic O Hydraulic (ator) © Hydraullo (oi) htinimurn / Maximum Driver Medium Pressure Avallable at Point of Use (specify): PSIG Failure Mode on Loss of Pneumatic or Hydraulic Pressure (check ono) Fal Freo Fall Close Fail Open 0 Fallin Last Postion C1 Manufacturer: Model Number: [Actuator Torque Output @ Minimum Driver Medium Pressure Av [control Devies=On/OMt Applleation®: Solenoid Valve, Single Col (ct) Fieldbus Protocat: Solenoid Valve, Dual Coll (cr) Fieldbus Protocok Solenoid Valve, Dual Col, 5-posiion, center closed Voltage: (or) Fieldbus Protocol: Manufacturer: ‘Model Number: Throttling Applications (Moves Inirequentiy)