‘American Water Works Association ANSI/AWWA (515-01 (Revision of ANSVAWNWA 0515-99} a AWWA STANDARD FOR REDUCED-WALL, RESILIENT-SEATED GATE VALVES FOR WATER SUPPLY SERVICE aA 4 Return to |) List of Standards. fective date: January 1, 2002, Firot edition approved by AWWA Board of Directors Jan. 24, 1999, ‘This edition approved: June 17, 2001 Approved by American Nationa Stondards Institute: October 50, 2001, AMERICAN WATER WORKS ASSOCIATION 6666 West Quincy Avenue, Denver, Colorado 80235 wonwawrwa.orgAWWA Standard ‘This document is an American Water Works Association (AWWA) standard. It is not a specification, AWWA stondards describe minimum requirements and do not contain all of the engineering and ad. ‘ministrative information normally contained in specifications. The AWWA standards nsvally contain, options that must be evaluated by the usor of the ctandard. Until each optional feature is sposified by tho user, the product or gervieo ie not fully dofined. AWWA publication ofa standard does nat consti- tute endorsement of any product or product type, nor does AWWA test, certify, or approve any prodvet. ‘Tho use of AWWA standards is entirely voluntary. AWWA standards are intended to represent a con- sencus of the water supply industry that the product deseribed will provide satisfactory service. When. AWWA revisos or withdraws this standard, an official notice of action will be placed on the first page of the classified advertising section of Journal AWWA. The action beoomes effective on the first day of ‘the month following the month of Journal AWWA publication ofthe official notice, American National Standard ‘An American National Standard implies a consensus of those substantially concerned with its scope ‘and provisions. An American National Standard is intended as a guide to aid the manufacturer, the consumer, and the general public. The existence of an American National Standard dees not in any respect preclude anyone, whether that person has approved the standard or not, from manufacturing, marketing, purchasing, or using products, processes, or procedures not conforming to the standard, American National Standards are subject to periodic review, and users are cautioned to obtain the lal est editions. Products of goods made in conformity with an American National Standard are encour aged to state on their own responsibilty in advertising and promotional materials or on tags or labels that the goods are produced in conformity with particular American National Standards. Caurion Notice: The American National Standards Institute (ANSD approval date on the front cov- er ofthis standard indicates completion of the ANSI approval process. This American National Stan- dlard may be revised or withdrawn at any time. ANSI procedures require that action be taken to reaffirm, rovise, or withdraw this standard no later than fivo years from the date of publication, Par- ‘chaore of Amorican National Standards may roceive current information on all standarde by calling ‘ox writing the American National Stondards Institute, 25 W, 43rd St., Fourth Floor, New York, NY 10036; (212) 642-1900, All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, eocording, ar any information or retrieval system, ‘except in the form of brief excorpis oF quotations for review purposes, without the written permission of the publisher Copyright © 2001 American Water Works Association Printed in USA 20010 Copyright American Water Works AssociationCommittee Personnel ‘The AWWA standards subcommittee that reviewed this standard had the following personnel at the time of approval: Roland L. Larkin, Chair SK Batra, Detroit Water & Sewerage Department, Detroit, Mich Jerry Bottenfield, Clow Valve Company, Oskaloosa, Iowa M.H. Burns, Denver Water Department, Denver, Colo. L.R. Dunn, U.S, Pipe & Foundry Company, Birmingham, Ala. L.W. Fleury J, Meuller Group, Smithfield, R.L Steve Flora, M&H Valve Company, Anniston, Ala, JJ. Gemin, Barth Tech (Canada) Inc., Kitchener, Ont, ‘DR. Ingalls, Bast Jordan Iron Works Inc., Bast Jordan, Mich, RL, Larkin, American Flow Control, Birmingham, Ala. Randy Looney, American AV Co., Fresno, Calif ‘Td, Mettler, Waterous Company, South St. Paul, Minn, cawwa) (awwa) cawwa) cawwa) cawwa) cAwwa) cawwa) cAwwa) cawwa) cawwa) cAWWwa) ‘The AWWA Standards Committoo on Gate Valves and Swing Check Valves, which reviewed and approved this standard, had the following personnel at the time of approval: Joseph J. Gemin, Chair ‘Thomas M. Bowen, Vice-Chair Roland L. Larkin, Secretary Consumer Members S.K. Batra, Detroit Water & Sewerage Department, Detroit, Mich. M.O. Beagle, Lansing Board of Water & Light, Lansing, Mich. ‘TM. Bowen, Manchester Water Works, Manchester, NI. MH. Burns, Denver Water Department, Denver, Cole, KW, Gruber, East Bay Municipal Utility District, Oakland, Calif CH, Kersey, Pucker Young Jackson ‘Tull Ine., Detroit, Mich, S.D, Tucker, Los Angeles Water & Power, Los Angeles, Calif 2001© Copyright American Water Works Association. cawwa) cawway cawway cawwa) cawwa) (awwa) cawwa)General Interest Members RL. Claudy Jr, Orlando Utilities Commission, Orlando, Fla, AV. Fonley, Orange, Calif. dl. Gemin, Barth Tech (Canada) Ine,, Kitchener, Ont. S.J. Medlar, Camp, Dresser & MeKoo Ine,, Edison, NJ EM. Misichko,” Underwriters Laboratories, Northbrook, Il, MS. Solomon, Winzler & Kelly Consulting Engineers, Santa Rasa, Calif EE Straw, ISO Commercial Risk Services Ine., Duluth, Ga. ‘ER, Volz, URS Greiner Inc., Colorado Springs, Colo. JH, Wilber,* Standards Engineer Liaison, AWWA, Denver, Colo, Ken Zastrow, Underwriters Laboratories, Northbrook, II. Producer Members Jerry Bottenfield, Clow Valve Company, Oskaloosa, Iowa LR. Dunn, US. Pipe & Foundry Company, Birmingham, Ala, Les Engelmann, Watts Industries, Woodland, Calif. LW. Fleury Jr, Mueller Group, Smithfield, RL Steve Flora,* M&H Valve Company, Anniston, Ala ‘DR. Ingalls, Kast Jordan Iron Works Inc., East Jordan, Mich, R.L. Larkin, American Flow Control, Randy Looney, American AVK Compa ‘Tul. Mettler,* Waterous Company, South St. Paul, Minn, MP Yoke,* Anniston, Ala. emingham, Ala, 1y, Fresno, Calif, Alternate ‘Liaison, nonvoting 2001 Copyright Amer san Water Works Association (AWWA) (AWWA) cawwa) (NEWWA) cAWWA) cAwwa) aso) cawwa) cawwa) cawwa) (Miss) cawwa) cawwa) cawwa) (awwa) (awa) (awwa) (AWWA) cawwa) cAWWa)Contents All AWWA standards follow the genoral format indicated subsequently. Some variations from this format may be found in a particular standard. see PAGE sc PAGE, Foreword 44 Detailed Design saronrennrnnnnnnian 1 Introduction... vii 4.5 Fabrication 16 LA — Background... vii on erennee ee vi 8 Verification LG Acceptance vii 8.1 Testing. Soa Tl Special Ieaues. ig 52 Plant Inspection and Rejection wesw. 18 I Use of This Standard... ik 6 Delivery TILA Purchaser Options and eaeeheeas fe eee ¥© 62 Proparation of Shipment. 18 HILB Modification to Standard X43 Aifdavit of Compliance a IV Major Revisions, x V Comments... x Appendix A Installation, Operation, and Standard ae rei ‘Maintenance of Reduced-Wall, feet ; Resilient-Seated Gate Valves wun. 19 1.2 Purpose 2 repiee 1.3 Application 2 1 Minimum ‘Thickness of Body 2 References 2 ‘and Bonnet 8 2 Excess Flange Thickness . 10 3 Definitions. 5 Stem and Stem Nut Copper Alloys... 11 4 Requirements 4 Minimum Diameter of Stem and 4. Data to Be Supplied by the Minimum Number of Tums Manufacturer to Open. . 13 42 Materials. 5 Diameter of Handwheels 8 43 General Design 8 6 — Goar Ratios 18 2001 Copyright Am an Water Works Association‘This page intentionally blank. 20016 Copyright American Water Works AssociationForeword This foreword is for information only and is nota part of AWWA C516. I, Introduetion, LA. Background. ‘This standard describes reduced-wall, resilient-seated gate valves with nonrising stems (NRS) and outside serew-and-yoke (OS&Y) rising stems, including tapping gate valves, for water supply service. The standard applies to water supply service having a pH range of 6.5 to 8.5 and a temperature from 33° to 125°F (0.6° to 52°C), ‘This standard inchides the unified numbering system (UNS) copper alloy designations in place of the A, B, C, D, and E grades of bronze, which are listed in ‘Table 1 of ANSI'/AWWA €500-98 and ANSVAWWA 509.94, AWWA required that the UNS alloy designations be substituted for the traditional grades A, B, C, D, E of bronze in all new standards and revisions. This is not intended to change the requirement for the types of bronzes to be used in the components of AWWA gate valves; it only changes the format for how those bronze requirements are designated. LB, History. ‘The first edition of AWWA C509 Standard for Resilient-Seated Gate Valves was published in 1980. ANSVAWWA C509 includes body and bonnet. parts of either gray or ductile cast iron with shell-wall thicknesses equal to those of the ANSVAWWA C500, Standard for Metal-Seated Gate Valves, which was first issued in 1952 as AWWA C500, but had its roots going back to the first AWWA standard for gate valves adopted June 24, 1913. In 1999, the AWWA Standards Committee on Gate Valves and Swing Check Valves received authorization from the AWWA Standards Council to prepare a standard covering reduced-wall, resilient-seated gate valves, Just as other recent AWWA standards have been developed as a result of the attendant strength of ductile iron (for pressure pipe and compact fittings), this standard results from its application for gate valves. ‘The Manufacturer's Standardization Society of the Valves and Fittings Industry (MSS) has played an important role in developing this standard, Founded in 1924, American National Standards Institute, 25 West 4rd Street, Fourth Floor, New York, NY 10086. 20016 Copyright American Water Works AssociationMSS has had official organizational representation on AWWA standards committees, dealing with valve and hydrant products since 1950, LLC. Acceptance. In May 1985, the US Environmental Protection Ageney (USEPA) entered into a cooperative agreement with a consortium led by NSF Intemational (NSF) to develop voluntary third-party consensus standards and a certification program for all direct and indirect drinking water additives. Other mombers of the original consortium included the American Water Works Association Research Foundation (AWWARF) and the Conference of Stato Health and Environ- mental Managers (COSHEM), The American Water Works Association (AWWA) and the Association of State Drinking Water Administrators (ASDWA) joined later. In tho United States, authority to regulate products for use in, or in contact with, drinking water rests with individual states.” Local agencios may choose to impose requirements more stringent than those required by the state. To evaluate the health effects of products and drinking water additives from such produets, state ‘and local agencies may use various references, including, 1, An advisory program formerly administered by USEPA, Office of Drinking Water, discontinued on Apr. 7, 1990. 2, Specific policies of the state or local agency. 3. ‘Two standards developed under the direction of NSF, ANSUNSK* 60, Drinking Water Treatment Chomicals—Health Effects, and ANSUNSF 61, Drinking Water System Components—Health Effects. 4, Other references, including AWWA standards, Food Chemicals Codes, Water Chemicals Codes,’ and other standards considered appropriate by the state or local agency. Various certification organizations may be involved in certifying products in accordance with ANSUNSF 61, Individual states or local agencies have authority to accept or accredit certification organizations within their jurisdiction. Accreditation of certification organizations may vary from jurisdiction to jurisdiction. Annex A, “Toxicology Review and Evaluation Procedures,” to ANSUNSF 61 does not stipulate a maximum allowable level (MAL) of a contaminant: for substances not, ‘Persons in Canada, Mexico, and non-North American countries should contact the appropriate authority having jurisdietion. ‘NSF International, 789 N. Dixhoro Ré., Ann Arbor, MI 48105, ‘Both publications available from National Academy of Sciences, 2102 Constitution Ave. NW, Washington, DC 20448, 2001 Copyright American Water Works Associationregulated by a USEPA final maximum contaminant level (MCL). The MALe of an unspecified list of “unregulated contaminants” are based on toxicity testing guidelines (nonearcinogens) and risk characterization methodology (earcinogens). Use of Annex A procedures may not always be identical, depending on the certifier. AWWA 515-01 does not address additives requirements. Thus, users of this standard should consult the appropriate state or Jocal agency having jurisdiction in order to 1. Determine additives requirements, including applicable standards. 2. Determine the status of certifications hy all parties offering to certify products for contact with, or treatment of, drinking water. 8. Determine current information on product certification. UL, Special Issues. ‘This standard has no applicable information for this section, JIL, Use of This Standard. AWWA has no responsibility for the suitability ‘or compatibility of the provisions of this standard to any intended application by any user: Accordingly, each user of this standard is responsible for determining that the standard’s provisions are suitable for and compatible with that user's intended application, TILA, Purehaser Options and Alternatives. ‘The following items should be included in the purchaser's specifications: 1. Standard used—that is, AWWA C515, Standard for Reduced-Wall, Resil- jent-Seated Gate Valves for Water Supply Service, of latest revision, 2, Whether or not the purchaser requires all cast ferrous valve components to be made of duetile iron, 8. Size and type of valve, NRS or OS&Y (See. 1.1). 4. Quantity required 5. Whether the valve is handwheel or wrench-nut operated and the direction in which the handwheel or wrench nut shall turn to open (Sec. 44.7). 6. Catalog data, net weight, and assembly drawings to be provided by the manufacturer (See. 4.1), if required. 7. Affidavit of compliance (See. 6.8), if required. 8. Whether or not records of tests specified in Sec. 6 are to he provided. 9, Whether or not the valve will be subjected to water that promotes corrosion and requires the use of alternative materials as described in See, 4.2.2.3, 200 1 Copyright American Water Works Association10. Whether or not the valve will be used in a corrosive environment (Sec, 1.1.8) determined by methods described in AWWA M27. 11, Type of valve ends—flanged (Sec. 4.4.1.3.1), tapping valve flange (Soe. 4.4.1.3.4), mechanical joint (Soc. 4.4.1.3.2), or push-on joint (See. 4.4.1.8.3), 12. Detailed description of wrench nut, if not in accordance with Sec, 4.4.7. 13. Special markings (Sec. 6.1), if required 14, Whether or not bolting material with physical and chemical properties other than ASTM A807 is required (See. 4.4.4). It is recommended that the purchaser verify with the supplier the appropriateness of any alternative bolting materials required. What alternative, if any, is desired in the type of rustproofing for holts and nuts (See. 4.4.4) 15. Cutter diameter must be specified for tapping valves (Sec. 4.3.2). Note: Tapping machine shell cutters are made in either full size (outside diameter [OD] is full nominal size) or undersize (OD is less than full nominal size, ie, usually % in, (13 mm) less [MSS SP-113)). The purchaser should specify the size of the shell cutter the valve must: accept, 16. Special packaging for shipment as may be required for protection of coatings. ULB. Modification to Standard. Any modifieation ta the provisions, defini- tions, or terminology in the standard must be provided in the purchaser's specifications. IV. Major Revisions. Major revisions made to the standard in this edition include the following: 1, Bin, and 18 in, through 36 in. have been added to the standard, 2, Table & has been expanded to add new alloys for stem nuts. V. Comments. If you have any comments or questions about this standard, please call the AWWA Volunteer and ‘Technical Support Group, (903) 794-711 ext, 46288, PAX (803) 795-7608, or write to the group at 6666 W. Quincy Ave., Denver, CO 80286. 2001 Copyright American Water Works Association‘American Water Works Association \ ANSVAWWA C515-01 (rst Edition) AWWA STANDARD FOR REDUCED-WALL, RESILIENT-SEATED GATE VALVES FOR WATER SUPPLY SERVICE SECTION 1: GENERAL See. 1.1 Scope ‘This standard describes reduced-wall, resilient-seated gate valves with nonris: ing stems (NRS) and outside serew-and-yoke (OS&Y) rising stems, including tapping gate valves, for water supply service having a temperature range of 33° to 125°F (0.6 to 52°C). These valves are intended for applications where fluid velocity does not exceed 16 sec (4.9 m/sec) when the valve isin the full open position L11 Sizes, This standard describes nonrising stom resilient soated gato valves 8-in. (75-mm) NPS" through 86-in. (200-mm) NPS and outside serew and yoke (OSGY) rising stem valves, Sein. (75-mm) NPS through 16-in, (400-mm) NPS. Sizes refer to the nominal diameter of the waterway through the inlet and outlet connections and the closure area 112. Valve pressure rating. ‘The minimum design working water pressure shall be 200 psig (1,380 kPa) for all sizes. *Nominal pipe size 1 2001© Copyright American Water Works Association2. AWWAC516-01 11.8 Conditions and materials not covered. ‘This standard is not intended to describe special conditions of installation or operation, such as built-in power drive, installation im unusually corrosive soil, conveyance of unusually corrosive water, or excossive water hammer. These conditions aro beyond the intended scope of this standard and require special consideration in design and construction. Joint accessories for end connections, such as bolts, gaskets, glands, and follower rings, are not described in this standard See. 1.2 Purpose ‘The purpose of this standard is to provide purchasers, manufacturers, and suppliers with the minimum requirements for reduced-wall, resilient-seated gate valves for water supply service, including materials, design, testing, inspection, rejection, marking, and shipping, Sec. 1.8 Application ‘This standard can be referenced in specifications for purchasing and receiving reduced-wvall, resilient-seated gate valves for water supply service. The stipulations of this standard apply when this document has been referenced and then only to reducod-wall, resilient-seated gate valves for water supply service. SECTION 2: _REFERENCES ‘This standard references the following documents. In their latest editions, they form a part of this standard to the extent specified within this standard, In any case of conflict, the requirements of this standard shall prevail. ANS ANSI B16.1—Cast Iron Pipo Flanges and Flanged Fittings, Claes 25, 125, and 1" AS-56BA—Acrospace Size Standard for O-rings. ANSI B16.10—Fuce-To-Face and End-To-End Dimensions of Valves. ANSI B18.2.1— juare and Hex Bolts and Screws Inch Series Including Hex Cap Serows and Lag Serows. ANSI B18.2.2~Square and Hex Nuts (ISO 272), “American National Standards Institute, 25 West, 48rd Street, Fourth Floor, New York, NY 10036. 20010 Copyright American Water Works Association[REDUCED-WALL, RESILIENTSEATED GATE VALVES 3 ANSUAWWA (1110/A21.10—-Amorican National Standard for Ductile-Iron and Gray-Iron Fittings, 3 In, Through 48 In. (76 mm through 1,219 mm), for Water. ANSVAWWA CILVA21.11—American National Standard for Rubber-Gasket Joints for Ductile-Lron Pressure Pipe and Fittings. ANSV/AWWA C153/A21.53—American National Standard for Ductile-Iron Gom- pact Fittings for Water Service, ANS/AWWA C550—Standard for Protective Epoxy Interior Coatings for Valves and Hydrants, ANSVAWWA. €600—Installation of Ductile-Iron Water Mains and ‘Their Appurtenances. ASTM" A27—Standard Specification for Steel Castings, Carbon, for General Applications, ASTM A126—Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings, ASTM A153/A153M_Standard Specification for Zine Coating (Hot-Dip) on Iron and Stool Hardware. ASTM A307—Standard Specification for Carbon Steel Bolts and Studs, 60,000 PSI Tensile Strength, ASTM A395/A395M—Standard Specification for Rerritie Ductile Iron Pres- sure-Retaining Castings for Use at Elevated Temperatures, ASTM A596—Standard Specification for Ductile Iron Castings. ASTM B1G/B16M—Standard Specification for Free-Cutting Brass Rod, Bar and Shapes for Use in Screw Machines. ASTM B62—Standard Specification for Composition Bronze or Ounce Metal Castings ASTM B98—Standard Specification for CopperSilicon Alloy Rod, Bar, and Shapes. ASTM B124/B124M—Standard Specification for Copper and Copper Alloy Forging Rod, Bar, and Shapes. ASTM B138—Standard Specification for Manganese Bronze Rod, Bar, and Shapes. "American Socioty for Tasting and Materials, 100 Barr Harbor Dr, West Conshohocken, PA 19428-2959, 20016 Copyright American Water Works Association4 awwa 0515-01 ASTM B154—Standard ‘Test Method of Mereurous Nitrate Test for Copper and Copper Alloys. ASTM B283_Standard Specification for Copper and CopperAlloy Die Forgings (Hot Prossed). ASTM B584—Standard Specification for Copper Alloy Sand Castings for General Applications. ASTM B633Standard Specification for Hlectrodeposited Coatings of Zine on Tron and Steel. ASTM B763—Standard Specification for Copper Alloy Sand Castings for Valve Application. ASTM B766—Standard Specification for Blectrodeposited Coatings of Cad- ium, ASTM B824—Standard Specification for General Requirements for Copper Alloy Castings, ASTM D895—Standard Test Methods for Rubber Proporty—Compression Set, ASTM D429—Standard Test Methods for Rubber Property—Adhesion to Rigid Substrates. ASTM D471—Standard Test Method for Rubber Property—Erfeet of Liquids, ASTM D1149—Standard ‘Test Method for Rubber Deterioration—Surface Ozone Cracking in a Chamber (Flat Specimen). ASTM D2000—Standard Clessification System for Rubber Products in Automo- tive Applications. Fed. Spec.” HH-P-106d—Packing; Flax or Hemp. Fed. Spec. TT-C-494b—Coating Compound, Bituminous, Solvent Type, Acid Resistant. MSS’ SP-9—Standard Practice for Spot Facing for Bronze, Tron, and Steel Flanges. MSS SP.60~Standard Practice for Connecting Flange Joint Between Tapping Sleeves and Tapping Valves. Redeval Specifications axe available from Naval Publications and Form Conter, 6801 ‘Tabor Avo, Philndolphia, PA 19120, ‘¥Manufneturers Standardization Society of the Valve and Fittings Industry, 127 Park St, NIE., Vienna, VA 22180, 20014 Copyright American Water Works AssociationRBDUCED-WALL, RESILIENTSEATED GATE VALVES. 5 MSS SP.113—Standard Practico for Connecting Joint Between Tapping Machines and Tap; ANSI/SAE AS 568A" Aerospace Size Standard for O-Rings. ng Valves. SECTION 3: DEFINITIONS ‘The following definitions shall apply in this standard: 1. Cosmetic defect: Blemishes that have no effect on the ability of the component to meet the structural design and production test requirements of this standard. Should the activity of plugging, welding, grinding, or repairing of the blemish cause the component to fail these requirements, the blemish may not be considered a cosmetic defect. 2. Flanged joint: ‘The flanged and bolted joint as described in ANSVAWWA CL10/A21.10 or ANSI B16.1, Class 125, 3. Manufacturer: ‘The party that manufactures, fabrieates, or produces mate- rials or products. 4, Mechanical joint: The gasketed and bolted joint as described in ANSW AWWA C110/A21.10, ANSVAWWA C1LV/A21.11, or ANSUAWWA GI59/A21.53. 5. NPS: Nominal pipe size. 6. Purchaser: ‘The person, company, or organization that purchases any materials or work to be performed, Push-on joint: The single rubber-gasket joint as described in ANSUAWWA CLVAgL.A1, 8. Structural defect: Flaws that cause the component to fail the structural design or test requirements of this standard, This includes but is not limited to imperfections that result in leakage through the walls of a casting, failure to meet ‘minimum wall thickness requirement, or failure to meet production tests. 9. Supplier: ‘The party that eupplies materials or services. A supplier may or may not be the manufacturer. 10. Tapping valve: A special gate valve designed with end connections and an ‘unobstructed waterway to provide proper alignment and positioning of a tapping sleeve, valve, and machine for tapping pipe dry or under pressure. **Speiaty of Automotive Engincors, 400 Commenwealth Dr, Warrendsle, PA 16096, 2001 Copyright American Water Works Association6 awwa.C515-01 SECTION 4: REQUIREMENTS Sec. 4.1 Data to Be Supplied by the Manufacturer If requested by the purchaser, the manufacturer or supplier shall provide the following information when supplying reduced-wall, resilient-seated gate valves. 411 Catalog data. ‘The manufacturer shall supply catalog data, including ‘Mustrations and a parts list that identifies the materials used for various parts. The information shall be in sufficient detail to serve as a guide in the assembly and disassembly of the valve and for ordering repair parts. 4.1.2 Weight information, The manufacturer shall provide a statement of the net assembled weight for each size of valve exclusive of joint accessories, 4.1.3 Assembly drawings. The manufacturer or supplier shall submit to the purchaser one set of drawings showing the principal dimensions, construction details, and materials used for all parts of the valve. All work shell be done and all valves shall be provided in accordance with these drawings after the drawings have been reviewed and accepted by the purchaser. Sec, 4.2 Mater Is Matorials shall comply with tho requirements of the Safe Drinking Water Act and other federal, state and local requirements, Legislation is subject to chango; therefore, it is the manufacturer and purchaser's responsibility to verify the current requirements of federal, state, and local regulations. 4.2.1 General, When reference is made to AWWA, ANSI, ASTM, or other standards, it shall be understood that the latest revision thereof shall apply: All materials used in valves produced according to this standard shall conform to the requirements stipulated in the following sections, 4.2.2 Physical and chemical properties, The requirements of AWWA, ANSI, ASTM, or other standards referenced in this text shall govern the physical and chemical characteristics of the valve components. Whenever valve components are to be made in conformance with AWWA, ANSI, ASTM, or other standards that include test requirements or testing procedures, the manufacturer or supplier shall comply with those procedures. The records of all tests shall, if roquired by the purchaser’s specification, be made available to the purchaser 4.2.2.1 Gray iron, Gray iron shall conte ASTM A126, Class B, ‘m to or exceed the requirements of 2001© Copyright American Water Works AssociationREDUGHD.WALL, RESILIENT ‘ATED GATE VALVES. 4.2.2.2 Ductile iron, Ductile iron shall conform to the requirements of ASTM A395 or ASTM A536. In addition, ductile iron shall contain no more than 0.08 percent phosphorus, 42.23 Copper alloys. Copper alloys used in valves shall comply with the following: 42.2.3.1 Copper alloy valve components shall be made to ASTM-recognized alloy specifications with Unified Numbering Systom for Motals and Alloys (UNS)" designations. Copper alloys are not limited to those specified in this standard. All copper alloys, however, must meet the performance requirements of this standard, including, but not limited to, minimum yield strength, chemical requirements, and corrosion resistance. 4223.2 Any copper alloy used in the cold-worked condition shall be capable of passing the mercurous nitrate test in accordance with ASTM B164 to minimize susceptibility to stress corrosion. 4.2.2.3.3 Waters in some areas have been shown to promote corrosion in the form of dezincification or dealuminization, Copper alloys that contain more than 16 percent zine shall not be used in these waters, Ifaluminum bronze is used, the alloys shall be inhibited against dealuminization 42.234 Copper alloys that contain more than 16 percent zine shall not contain less than 57 percent copper. 4223.5 Copper alloys that contain 16 percent zine or less shall not contain less than 79 percent copper. 4.2.2.3.6 Valve components manufactured from some grades of manganese, bronze, or some other materials are subject to stress corrosion. The manufacturer shall design the valve and select materials to minimize stress corrosion. 4223.7 Copper alloys that contact drinking water shall not contain more than 8 pereent lead. (US Safe Drinking Water Act Amondments of 1986) 4224 Gaskets, Gasket material shall be made of inorganic mineral fiber, rubber composition, or paper that is free from corrosive ingredients, O-rings or other suitable elastomeric seals may be used. 42.2.5 O-rings, O-rings shall moot the requirements of ASTM 2000 and have physical properties suitable for the application. ‘Joint publication of ASTM and SAB (ASTM DS-56B/SAE HS-1086, 1995). 2001© Copyright American Water Works Association3 AWWACEIEO1 4.2.26 Coatings. Unless otherwise specified by the purchaser, valve coatings, as required in Sec. 4.5.2, shall meet the performance requirements of Sev. 3.4.5 of Fed. Spec. TT-C-494B for water-based enamel coating or black asphalt coatings or ANSVAWWA C550 coatings, oF equal 4.2.2.7 Blastomers. Elastomers shall comply with the following: a, Rubber seats shall be resistant to microbiological attack, copper poisoning, and ozone attack ». Rubber-seat compounds shall contain no more than 8 parts por million (ppm) of copper of the rubber material n and shall include copper inhibitors to prevent copper degradation ©. Rubber-seat compounds shall be capable of withstanding an ozone resistance test whon tested in accordance with ASTM D1149. The tests shall be conducted on unstressed samples for 70 hr at 104°F (40°C) with an ozone concentration of 500 parts per billion (ppb) without. visible cracking in the surfaces of the test samples after a test, 4, Rubber-seat compounds shall have a maximum compression ect value of 20 percent when tested in accordance with ASTM D395, method B, for 22 hr at 158°F (70°0), @. Rubber-seat compounds shall contain no more than 1.5 parts of wax paper, 100 parts of rubber hydrocarbon, and shall have less than 2 percent volume increase when tested in accordance with ASTM D471 after being immersed in distilled water at 73.4°F # 2°F (23°C # 1°C) for 70 hr. Reclaimed rubber shall not be used. £ Rubber-seat compounds shall be free of vegetable oils, vegetable oil derivatives, animal fats, and animal oils. Sec. 4.3. General Design 43.1 Structural design. All parts of all valves shall he designed to withstand (2) an internal test pressure of twico the rated design working pressure of the valve; and (2) the full-rated internal working pressure when the closure member is eycled ‘once from a fully open to a fully closed position against the full-rated unbalanced working water pressure. In addition to these pressure requirements, the valve assembly and mechanism shall be capable of withstanding an input torque as follows: S-in, (75-mm) and 4-in. (100-mm) NPS—200 fL-lb (270 Nm); 6-in, (150-mm), 8-in, (200-sm), 104in, (250-mm)}, 12-in. (200-mm), L4-in. (350-mm), 16-in. (400-mm) NPS— 800 fL1b (406 Nm), For sizes larger than 16 in. (400 mm), consult the manufacturer. 2001 Copyright American Water Works AssociationREDUGED-WALL, RESILIENTSEATED GATE VALVES 9 48.2. Size of waterway. With the valve opon, an unobstructed waterway shall be provided. The waterway shall have & diameter equal to or larger than the full nominal diameter of the valve. For tapping valves, the size of the waterway shall include appropriate clearance for the diameter of the tapping machine cutter recommended by the valve manufacturer Sec. 4.4 Detailed Design 44.1 Body and bonnet. 44.1.1 Material. ‘The body and bonnet shall be made of ductile iron. 44.1.2 Shell thickness. Shell thickness at no point shall be less than the minimum metal thickness shown in ‘Table 1 44.18 Valve ends. End connections shall conform to one of the following requirements, 44.13.1 Flanged ends. ‘The end flanges of flanged valves shall conform to dimensions and drillings of ANSVAWWA C110/A21.10 or ASME/ANSI B16.1, Class 125, unless explicitly provided otherwise in the purchaser's specifications, Unless spot-facing is required by the purchaser's specifications, the bolt holes of the end flanges shall not be spot-faced except when the thickness at any point within the spot-face area, as defined in MSS SP-9, exceeds the required minimum flange thicknoss of ASMEVANSI B16.1 by more than indicated in Table 2 or if the flange is not sufficiently flat. Ifthe foregoing limit is exceeded, either spot-facing or backfacing Table 1 Minimum thickness of body and bonnet ‘Valve Diameter (NPE ‘Minimum Metal Thickness in nm) in (om) 3 @) 0.20) wa 4 100) oat (ay 6 150) oa a) 8 200) 04 (eo) 0 250) p26 en w (300) 0.8 on u 350) 0.45, ay 6 (400) 050 a2 8 (450) 056 asa) 20 600) ps6 14.2) a (600) 062, as.) 30 (750) 1.06 (269) 26 (900) 131 33.) 200112 Copyright American Water Works Association10 AWWA CB15- ot Table 2. Excess flange thickness Nominal Valve Size (NPS) xoess Thickness (maximam) in am) in fmm) 312 (75-800) ts ea 14-24 (250-600) %e 4s 30-96 (750-900) Me a) may be used to meet the requirements. When required, all spot-facing shall be done in accordance with MSS SP-9, Bolt holes shall straddle the vertical conterline of the valve, unless otherwise specified by the purchaser, The laying lengths of flanged valves 12 in. (300 mm) and smaller shall conform to the requirements for double dise gate valves listed in Table 1 of ASMEVANSI B16.1 44.1.8.2 Mechanical-joint ends. Mechanicaljoint bell dimensions shall con: form to ANSVAWWA C110/A21.10, ANSUAWWA C11V/A21.11, or ANSVAWWA ©159/A21.53. Slots with the same width as the diameter of the bolt holes may be provided instead of holes in the bell {lange where the valve body and bonnet interfere with the joint assembly, 44.13.38 Push-on joint ends. Push-on joints shall conform to the require- ments of ANSVAWWA C111/A21.11 44.134 ‘Tapping-valve flanges. ‘The end flange of a tapping valve that forms a joint with the tapping sleeve shall conform to the dimensions of MSS SP-60 in sizes 84in, (75-mm) through 12-in. (300-m:m) NPS, For larger sizes, flange dimensions shall be as agreed ta by the purchaser and supplier. ‘The connecting flange of the tapping valve mating with the tapping machine must be parallel and concentric with the opposite flange and concentric with the waterway to provide proper alignment for the tapping operation. The end flange of a tapping valve that forms a joint with the tapping machine shall conform to the dimensions of MSS SP-113. 44.14 Yokes on OSRY valves. On OS&Y valves, the yoke on bonnets may be integral or of bolted-on construction. If the yoke is not an integral part of the bonnet, it shall be made of duetile iron or gray iron, The design shall be such that a hand cannot be jammed between a yoke and the handwheel. 442 Gate. 4.42.1 Material. ‘The ferrous material of the gate shall be made of ductile iron or gray iron, or copper alloy (soe ‘Table 8 for coppor alloys). 2001© Copyright American Water Works AssociationREDUCED. LL, RESILIENTSEATED GATE VALVES 11 Table 3. Stem and stem nut copper alloys ‘Copper Alloy’ ASTM Specification Numbor Alloy Designation ‘ASTM B16 "UNS C3600 ASTD BI88: ‘UNS ce7500 ‘ASTM B283 Valve Stoms & Gates ASTM B283 UNS C67600 ASTM B98 ‘UNS C8610 UNS c36200 ASTM B84 ‘UNS C6500" ‘UNS C36700! ‘UNS C7600 ‘UNS c8650ot ASTM B63 ‘UNS C36z00t UNS Co9400 [UNS Go9500 ‘ASTM BG UNS 085600 ASTM Be2d ‘UNS Ceadoot Stem Nuts & Gates ASTM BI2Z4 UNS c37700 AST BS84 UNS 84400" UNS C83450 ‘UNS Ca6700t ASTM B163 UNS C8650" UNS C8670" ‘UNS C9520 UNS C95500 UNS Co5800 ‘UNS Co9400 UNS C99500 Alloys acwally used or specified not limited to those lsted—see See, 42.2.3. omplinnce with AWWA C515 requires the manufacturer to specify minimum mechanical or chemical require ‘xoced the minitnums required for thie ally by the AST spoifeaion)listd. 442.11 Resilient seats shall be bonded or mechanically attached to the gate. ‘The proof-of design test method used for bonding or valeanizing shall be ASTM D429; ‘either method A or method B. For method A, the minimum strength shall not be less, than 260 psi (1,725 kPa). For method B, the peel strength shall not be less than 76 Ibfin. (13.2 N/mm). All exposed mechanical attaching devices and hardware used to retain tho resilient soat chall be of a corrosion-rosistant material 44.3 Guides. If guiding is required to obtain shutoff, the design shall be such that corrosion in the guide area does not affect seating. 44.4 Bolting Bolting matorials, excluding joint accessories, shall have the physical strength requirements of ASTM A307 and shall have either regular square 2001 Copyright American Water Works Association32 Awwa 0515-01 or hexagonal heads with dimensions conforming to ANSI B18.2.1. Bolts, studs, and nuts shall be (1) cadmium-plated (ASTM B766) or zinc-coated (ASTM A153 or B633); or (2) rustproafed by some other process disclosed to and acceptable to the purchaser ‘The purchaser may specify bolts, studs, and muts made from a specified eorro- sion-resistant material, such as low-zine bronze, nickel-copper alloy, or stainless steel. 4.4.5 Stem and stem nut 44.5.1 Valve stems shall be made from copper alloys that have e yield strength of 20,000 psi (197,800 kPa) or greater (sce Table 3). 44.52 Stem nuts shall be made from copper alloys that have a yield strength of 14,000 psi (96,500 kPa) or greater (see ‘Table 8). 44.5.3 NRS stems. ‘The stom must have a thrust collar that. shell be made integral with the stem. 44.54 OSRY stems. OS&Y valve stems shall be of sufficient length so as to be at least flush with the top of the stem nut after the gate is fully closed. The design shall prevent any possibility of the gate leaving the stem or the stem turning during the operation of the valve, 44.55 Threads. The threads of stems and stem nuts shall be of Acme, modified Acme, stub Acme, or one-half V type. Stems and stem nuts shall be threaded straight and trae and shall work true and smooth and in perfect line throughout the lift of opening and thrust of closing the valve. 44.56 Diameter. ‘The stem diameters and turns to open shall be as shown in ‘Pablo 4 44.6 Siem sealing ‘The sealing system shall be designed to be watertight at, the rated working pressure of the valve. 44.6.1 NRS valves, 44.6.1.1 Matorials. A stem seal plate or O-ring packing plate shall be made of ductile iron or gray iron. Stem openings, if bushed, or stem-seal cartridges, shall be of a copper alloy, or a synthetic polymer with physical properties suitable for the application, Stem-seal plate bolts and nuts shall conform to the requirements as specified in Seo. 4.4 44.6.2 Stem-seal plate. On NRS valves, the stem opening, thrust bearing recess, and bonnet face of the stem-seal plate shall be machined or finished in a manner that will provide surfaces that are smooth and either parallel or perpendicu- lar to the stom axis within 0.5°. 20016 Copyright American Water Works AssociationREDUCED-WALL, RESILIENTSBATED GATE VALVES 18) 1um number of turns to open RS Valvor [OSEY Valves inimum Diameter Minimum Number Minimum Diameter of Minimum Number ofStem of Turns of Stem Stem Unthroaded Section of Turns of Stem (at base of thread)’ to Open. ‘and Thread OD! to Opent tom) te cum bx rm 3 ce) 08s cata) ° % aon 7 400) ost ca.) 2 1 3.0) 9 6 50) 1.000 (25.40) 8 Hy 88) 18 8 0) = 0005.40) mn 1% ony 25 10 5) L156) 20 oe G4) st 2 Gn) L188 GO) 38 % 9 3 M4 (850) 1350 G75) #2 Phe (6) 42 16 40) L438 388A) “3 vp a0) 48 18 450) 10254128) Bt 20 (500) 1.750 (4S) 40 24 (600) 1.868 (60.0) “8 30 (750) 1888.58) «0 3690 2800 168.50) 2 “The diameter of the stem at the base of the thread oF at any point below that portion shaped to rsdive the wrondh nut ‘on NES valves or the minimum diametor af the stom wnthreaded section and thread OD fer OSRY valves shal not be Tess han epeciied Outside diameter $Nisleos shown for 6-12 in, NPS sizes aco for singlo-osd hres, I's doubledend thres ie wsed, minimem tore bacome 13, 17,21, and 25 for sis 6-12 in. NPS incsive, 446.13 Stem seal. When an O-ring or other pressure-actuated stem seal is used, the design shall incorporate at least two such seals. ‘The dimensions of the O-rings shall be in accordance with SAE AS-568A. 44.62 OS&Y valves. 4462.1 Stuffing boxes. a, Material, Stuffing-box packing shall be made of flax conforming to Fed Spec, HH-P-106d or other appropriate material. Hemp, asbestos, or jute packing shall not be used. >. Stufling-hox dimensions. Stuffing boxes shall have a depth not less than the diameter of the valve stem. ‘The internal diameter shall be large enough to contain adequate packing to prevent leakage around the stom. © Installation, Stuffing boxes shall be packed properly and ready for service when valves are delivered to the purchaser. Stuffing-box bolts may need to he adjusted to stop lonkage at the time of installation, 20010 Copyright American Water Works Association1M awwa 0516.01 44622 Packing glands, gland followers, gland bolts, and gland-bolt nuts, ‘The packing gland assembly shall be of sotid, solid-bushed, or two-pieve design. Followers ray be formed as a flanged end on the gland or as a separate item, a, Packing glands. Packing glands shall be made of a eopper alloy, synthetic polymer, gray iron, or ductile iron b. Gland follower. Ifa gland follower is used, it shall be made of either ductile or gray iron, or a copper aly. ©. Packing-gland bolts and nuts, Gland bolts shall be made cithor of a copper alloy or rustproofed steel according to See. 4.44. Gland-bolt nuts shall be made of a copper alloy. 44.6.3 Stem-seal replacement. 44.6.3. NRS valves shall be designed eo that the seal above the stem collar can be replaced with the valve under pressure in the fully open position. 44.6.8.2 Design of OS&Y valves shall be such that the stuffing box ean be packed when the valves are in the fully open position and under pressure. 44.7 Wrench nuts and handwheels, Wrench nuts and handwheels shall be made of gray iron or ductile iron. Unless otherwise explicitly required by the purchaser's specifications, the wrench nuts shall be 11%e-in. (49.2-mm) square at the top, 2in. (60.8mm) square at the base, and 1%-in. (44.5-mm) high. ‘The outside diameter of handwheels shall not be less than those given in Table 6. Nuts shall have a flanged base on which shall be cast an arrow at least 2-in. (50.8-mm) long showing the direction of the opening. The word “OPEN,” in %-in, (12.7-mm) or larger letters, shall be east on the nut to indicate clearly the direction to turn the wrench when ‘opening the valve, Handwheels shal} be of the spoke type only. Webbed or dise types are not permissible. An arrow showing the direction to turn the handwheel to open the valve, with the word “OPEN” in %o-in, (12.7-mm) or larger letters in a break in the arrow shaft, shall be cast on the rim of the handwheel a0 as to be read easily. 44.71 Operating mechanism, NRS valves are to be supplied with wrench nuts or handwheels. OS&Y valves are to be supplied with handwheels 44.12 Direction of opening, ‘The standard direction of opening is counter clockwise as viewed from the top. Valves opening in the opposite direetion (clockwise) may be specified 44.18 Method of securing. Wrench nuts or handwheels shall be fitted to the valve stem on NRS valves. Handwheels shall be fitted to the stem nut on OS&Y valves. In both cases, they shall be secared by mechanical means. 2001 Copyright American Water Works AssociationREDUCED-WALL, RESILIENTSEATED GATE VALVES 15) Table 5 Diameter of handwheels* Size of Valve (NPS) ‘Minimum Diameter of Handwheol in a) in, nm) a 7B) 7 7a) 4 100) 10 (254) 6 aso) 1 (308) 200) M (356) 30 50) 16 (406) 2 (300) 16 (406) “For izes Targor than 12 in. (00 mo, consult the manufacturer 44.74 Color coding. Wrench nuts and handwheels that open the valve by turning to the right (clockwise) shall be painted red, and wrench nuts and handwheels that open the valve by turning to the left (counterclockwise) shall be painted black. 44.8 Gaskets Gaskets, O-rings, or other suitable elastomeric seals shall be used on all flanged joints intended to be watertight, 4.4.9 Gearing. If they are required by the purchaser's specifications, gears shall be accurately formed and smooth running, with a pinion shaft operating in bronze, self-lubricating, or permanently sealed antifriction bearing. 44.9.1 Material, Geared valves shall be equipped with steel, ductile-iron, or gray-iron gears. If cast-iron gears are provided, the pinion shall be steel]. Material for steel gears shall be ASTM AT Grade U-60-80 or equal 44.9.2 Gear cases, Valves using O-ring or V-type stem seals may have the gear case attached directly to the valve. When geared valves are provided, enclosed gear cases are reguired unless definitely excluded by the purchaser's requirements, 44.9.3 Indicators. When required by the purchase 's specifications, geared valves shall be equipped with indicators to show the position of the gate in relation to the waterway. 44.94 Gear ratio. Gear ratios shall not be less than those shown in Table 6, Table 6 Gear ratios, in (nm) 16-24 (400-600) 2 30-36 (750-800) al 20016 Copyright Americen Water Works Association16 Avrwa 0515-01 449.5 Input torque. ‘The maximum input torque shall be as recommended by the manufactur Sec. 4.5 Fabrication 45.1 Workmanship. 45.1.1 Interchangeable parts. AN parts shall conform to their required dimensions and shall be free from defects that could prevent proper functioning of the valve, All like parts of valves of the same model and size produced by the same manufacturer shall be interchangeable. 451.2 Castings. All castings shall be clean and sound without defects that ‘will weaken their structure or impair their service, Plugging, welding, or repairing of cosmetic defects is allowed. Repairing of structural defects is not allowed unless agreed to by the purchaser. Repaired valves shall comply with the testing requirements of this standard. Repairs within the bolt circle of any flange face are not allowed. 45.2 Coating. 4.5.2.1 Interior ferrous surfaces. A coating conforming to the performance requirements of ANSVAWWA C560 shall be applied to the interior ferrous surfaces of the body and bonnet that are in contact with liquid. Other exposed interior ferrous surfaces except finished or bearing surfaces chall be coated with a material specified in See, 42.26, 4.5.2.2 Exterior ferrous surfaces. A coating material as specified in Sec 4.2.2.6 shall be applied to all exterior ferrous surfaces. SECTION 3: VERIFICATION Sec. 5.1 Testing 5.11 Proof of design testing. 5.1.1.1 Hydrostatic gate test. One prototype valve of each size and class of the manufacturer's design shall be hydrostatically tested with twice the specified rated pressure applied to one side of the gate and zero pressure on the other side. The test is to be made in each direction across the gate for a minimum period of 8 min, ‘The manufacturer may make special provisions to prevent leakage past the seats, No part of the valve or gate shall remain visually deformed by the test 20016 Copyright American Water Works AssociationRDDUCED-WALL, RESILIENTSBATED GATE VALVES 17 5.1.1.2 Torque test. A prototype of each size shall be overtorqued in the dlosed and open positions to demonstrate that no distortion of the valve stem or damage to the resilient seat occurred as evidenced by the failure to seal at the rated pressure, The torque applied to the main valve stem shall be 250 ft-lb (340 Nan) for 3-in. (75-mm) and 4in, (100-mm) NPS valves; 350 ft-lb (475 Nm) for 6-in. (160-mm), 8-in, (200-mm), 10-in, (250-mm), and 12-in, (800-mm) NPS valves; 400 ft-lb (545 Nm) for L4-in (350-r0m), 16-in, (400-mm), 18-in, (450-mm), 20-in, (500-mm), and 24-in, (600-mm) NPS valves; 500 ft-lb (680 Nm) for 30-in, (750-mm) NPS velves and 600 ft-lb (820 Nm) for 36-in. (900-mm) NPS valves. 5.1.19 Leakage test. One prototype valve of each size shall be fully opened and closed to a seal for 500 complete cycles with sufficient flow that the valve is at tho rated working prossure for the pressure differential at the point of losing. The valves shall be drip-tight under the rated pressure differential applied alternately to each side of the gate after the completion of the tests. 5.1.14. Hydrostatic shell test. One prototype of each valve size shall be tested to 26 times the rated working pressure with the gate in the open position. For a period of 6 min, there shall be no rupture or eracking of the valve body, valve bonnet, or seal plate, Leakage at pressure-containing joints shall not be a cause for failure of the test, No part of the valve shall remain visibly deformed after the test, 5.1.2 Production testing. After manufacture, each gate valve shall bo sub- jected to operation and hydrostatic tests at the manufacturer's plant as specified in this section. 5.1.2.1 Operation test, Each valve shall be operated through a complete cycle to ensure proper functioning of all parts, Any defects in workmanship shall be corrected, and the test repeated until a satisfactory performance is demonstrated. 5.1.2.2 Shell test, A hydrostatic test pressure equal to twice the rated ‘working pressure of the valve shall be applied to the assembled valve with the gate in the open position. The test shall show no leakage through the metal, pressure- containing joints, or stem seals. 5.1.23 Seat test, A hydrostatic test shall be made from each direction at a minimum of the rated working pressure to prove the sealing ability of each valve from both directions of flow. The test shall show no leakage through the metal, pressure-containing joints, or past the seat. 20016 Copyright American Water Works Association18 AWWAC5I6-01 See. 2 Plant Inspection and Rejection All work performed according to this standard, except prototype testing, shall be subject to inspection and acceptance by the purchaser who shall have access to alll places of manufacture where these valves are being produced and tested, Any valve or part that may be determined as not conforming to the requirements of this standard shall be made satisfactory, or it shall be rejected and repaired or replaced by the manufacturer, Repaired valves must be acceptable to the purchaser and specifically accepted when submitted or resubmitted. Whether the purchaser has a representative at the plant or not, an affidavit of compliance may be required from the manufacturer as provided in Sec. 6.8 of this standard SECTION 6: DELIVERY Sec. 6.1 Marking Markings shall be cast on the bonnet or body, or stamped on a permanently affixed corrosion-resistant tag of each valve. Markings shall show the manufacturer's name or mark, the year the valve casting was made, the size of the valve, letters "C516," and the designation of working water pressure, for example, “200W.” Special ‘markings in addition to these ean be supplied when specified by the purchaser’s requirements on agreement between purchaser and manufacturer. Sec. 6.2. Preparation for Shipment Valves shall be complete in all details when shipped. Valves shall be drained before shipment, Handwheels and valve accessories may be packed separately Sec. 6.8 Affidavit of Compliance ‘The manafacturer shall, when required by the purchaser's specifications, provide the purchaser with an affidavit stating that the valve and all materials used in its construction conform to the applicable requirements of this standard and the purchaser's specifieations and that all tests specified in this standard have been performed and all test requirements have boen met, 200109 Copyright American Water Works AssociationAPPENDIX A Installation, Operation, and Maintenance of Reduced-Wall, Resilient-Seated Gate Valves This opmendis is for information anty and isnot a part of AWWA C515. SECTION A.1: GENERAL Resilient-seated gate valves form a significant component part of many fire-fight- ing or water-distribution systems. Failure of a resilient-seated gate valve in these systems, either as a result of faulty installation or improper maintenance, could result in extensive damage and costly repairs. In addition, many resilient-seated gate valves are installed in buried-service or underground applications. Problems or malfunctions of the valves because of faulty installation or improper maintenance can result in extensive and costly unearthing operations to effectively correct or clinsinate the problem, Many resilient-seated gate-valve problems and failures can be traced back to improper handling, storage, installation, operation, or maintenance procedures. SECTION A.2: UNLOADING All valves should be unloaded carefully. Each valve should be carefully lowered from the truck to the ground; it should nat be dropped. In the case of larger valves, forklifts or slings around the body of the valve or under the skids should be used for unloading. Only hoists and slings with adequate load capacity to handle the weight of the valve or valves should be used. Hoists should not he hooked into or chains fastened around yokes, gearing, motors, eylinders, or handwheels. Failure to carefully follow those recommendations is likely to result in damage to the valve. SECTION A.3: _ RECEIVING INSPECTION, Resilient-seated gate valves ehould be inspected at the time of receipt for damage during shipment, ‘The initial inspection should verify compliance with 19 20011 Copyright American Water Works Association20 AWWA.C515.01 spocifications, direction of opening, size and shape of operating nut, number of turns to open or close, and type of end connections. A visual inspection of the seating surfaces should be performed to detect any damage during shipment or scoring of the seating surfaces. Inspection personnel should look for bent stems, broken hand wheels, cracked parts, loose bolts, missing parts and accessories, and any other evidence of mishandling during shipment. Bach valve should be operated through ‘one complete opening-and-closing cycle in the position in which it is to be installed. SECTION A.4: STORAGE Valves should be stored indoors, If outside storage is required, the valves should be protected from weather elements, During outside storage, they should be protected from the weather, sunlight, ozone, and foreign materials. In colder climates where valves may be subject to freezing temperatures, it is absolutely essential to prevent ‘water from collecting in the valves. Failure to do so may result in a cracked valve casting or detorioration of the resiliont seat material SECTION A.5: INSTALLATION Instructions supplied by manufacturers should be reviewed in detail before valves are installed. At the job site prior (o installation, each valve should be visually inspected and any foreign material in the interior portion of the valve should be removed. A detailed inspection of the valve as outlined in Sec. A. should be performed prior to installation. See. A.5.1 Bolts All bolts should be checked for proper tightness and protected by the installer to prevent corrosion, either with a suitable paint or by polyethylene wrapping or other suitable means of corrosion protection, Sec. A.5.2 Underground Installation Valves in water-distribution lines shall, where practical, be located in easily accessible areas. A.52.1 During installation, there is the possiblity of foreign materials inadver- tently entering the valve. Foreign material can damage internal working parts during 20011 Copyright American Water Works AssociationREDUCED-WALL, RESILIENTSEATED GATE VALVES 21 operation of the gate valve. For this reason, gate valves should be installed in the closed position. Bach valve should be placed on firm footing in the trench to prevent selling and excessive strain on the connection to the pipe. Piping systems should be supported and aligned to avoid damage to the valve, A522 Avalve box or vault should be provided for each valve used in a buried service application. ‘The valve box should be installed s0 as not to transmit loads or stress to the valve, valve stem, or piping system, The valve box should be eontered over the operating nut of the valve with the box cover flush with the surface of the finished area or another level as directed by the purchaser. Valve boxes should be designed so that a traffic load on the top of the box is not transmitted to the valve stem or piping system, A528 Valves buried in unusually deep trenches have special provisions for ‘operating the valve. These are either a riser on the stem to permit a normal key te be used or a notation on valve records that a long key will be required. 5.24 When valves with exposed gearing or operating mechanisms are installed belowground, a vault designed to allow pipe clearance and prevent settling on the pipe should be provided. The operating nut should be accessible from the top opening of the vault with a valve key. The size of the vault should provide for easy removal of the valve bonnet and internal parts of the valve for purposes of repair, Consideration should be given to the possible entry of groundwater or surface water and to the need to provide for the disposal thereof See, A.5.3 Aboveground Installations Valves installed aboveground or in a plant piping system should be supported and aligned to avoid damage to the valve. Valves should not be used to correct misalignment of piping. Sec. A.5.4 Inspection After installation and before pressurization of the valve, all pressure-containing bolting bonnet, seal plate, packing gland, and end connections) should be inspested for adequate tightness to prevent leakage. In addition, an ingpestion should be made for adequate tightness of all tapped and plugged openings to the valve interior Proper inspection at this time will minimize the possibility of leaks after the piping system has heen pressurized 200189 Copyright American Water Works Assciation22 AWWACSIS-01 See, A.5.5 Testing To prevent time lost searching for leaks, it is recommended that valve excavations not be backfilled until pressure tests have been completed. After installation, it is desirable to test newly installed piping sections, including valves, at some pressure above the system design pressure, The test pressure should not exceed the rated working pressure of the valve. Afler the test, steps should be taken to relieve any trapped pressure in the body of the valve. ‘The resilient-seated gate valve should not be operated in either the opening or closing direction at differontial pressures above the rated working pressure. It should be noted that valves seat better at or near the rated working pressure of the valve. In addition, wear or foreign material may damage valve seating surfaces and may eause leakage (See AWWA 600), ec. A568 Records Once the valve is installed, the valve location, size, make, type, date of ingtallation, number of turns to open, direction of opening, and other information deemed pertinent should be entered on permanent records. Sec. A.5.7 Application Hazards Resilient-seated gate valves should not be installed in applications or for service other than those recommended by the manufacturer, The following list of precautions is not all inclusive but will help avoid some applications hazards, AS.1.1 Resilient-seated gate valves should not be imstalled in lines where service pressure will exceed the rated working pressure of the valve. A5.7.2 Resilientseated gate valves should not be used for throttling service unless the design is specifically recommended for that: purpose or accepted in advance by the manufacturer. 5.7.8 Resitient-seated gate valves should not be used in applications that are exposed to freezing temperatures unless sufficient flow is maintained through the valve or other protection is provided to prevent freezing. AS.7.4. Pipe, fittings, and valves installed in underground piping are generally joined with push-on or mechanical joints. These joints are considered unrestrained- type joints because no significant restraint against longitudinal separation is provided Gate valves should not be installed at a dead end or near a bend in a pipeline without proper and adequate restraint to support the valve and prevent it from 200140 Copyright American Water Works AssociationREDUCED-WALL, RESILIENTSEATED GATE VALVES 25, blowing off the end of the line. Rigid piping systoms incorporating flanged valves are not recommended for buried service. ‘Thrust blocks, restrained joints, or other means of restraint are needed on or adjacent to valves on pipelines or where unusual conditions exist, such as high internal pressures, adjacent fittings, or unsuitable soils, A.7.5 To prevent damage, 3:in. (75mm) NPS and 4in, (100-mm) NPS, resitient-seated gate valves should not be operated with input torgnes greater than 200 ft-lb (270 Nm), Gate valves 6-in, (150-mm) NPS to 16-in, (400-mm) NPS should not be operated with input torques greater than 300 f\-1b (406 Nm). SECTION A.6: _ MAINTENANCE Sec. A.6.1 Valve Exercising Each valve should be operated through a full cycle and returned to its normal position on a time schedule that is designed to prevent a buildup of tuberculation or other deposits that could render the valve inoperable or prevent a tight shutoff The interval of time between operations of valves in critical locations or valves subjected to severe operating conditions, should be shorter than for other less important installations, but it ean be whatever time poriad ie found to be satiefactary based on local experience. The number of turns required to complete the operation eycle should be recorded and compared with permanent installation records to ensure full gate travel When using portable, auxiliary power actuators with input torque capacities exceeding the maximum operating torques recommended in Sec. A.6.7.5, extreme care should be taken to avoid applying excessive torque to the valve stem. If the actuator has a torque-limiting device, it should he set below the values in Seo. 5.7.5. If there is no torque-limiting deviee, the recommended practice is to stop the power actuator three or four turns before the valve is fully opened or fully closed and complete the operation manually. Maintenance should be performed at the time a malfunction is discovered to avoid a retum trip to the same valve or to provent neglecting it altogether A. recording system should be adopted that provides a written record of valve location, condition, maintenanes, and each subsequent inspection of the valve, 20014 Copyright American Water Works Association24 AWWACSI5-01 See, A.6.2 Inspection Bach valve should be operated through one complete operating cycle. If the stem action is tight, the operation should be repeated several times until proper operation is achieved. With the gate in the partially opon position, a visual inspection should be performed, where practical, to check for leakage at all joints, connections, and areas of packing or seals, If leakage is observed, all defective O-rings, seals, gaskets, or end-connection sealing members should be replaced. If the leakage cannot be corrected immediately, the nature of the leakage should be reported promptly to those who are responsible for repairs, If the valve is inoperable or irreparable, its location should be dlearly established to prevent loss of time for repair crews. The condition of the valve and, if possible, the gate position should be reported to the personnel responsible for ropairs. In addition, fire departments and other appropriate municipal departments should be informed that the valve is out of service. Sec. A.6.3 Record Keeping ‘To carry out a meaningful inspection and maintenance program, it is escential that the location, make, type, size, and date of installation of each valve be recorded. Depending on the type of record-keeping system used, other information may be entered in the permanent record, When a resilient-seated gate valve is inspected, an entry should be made in the permanent record indicating date of inspection and condition of the valve. If repair work is necessary, it should be indicated, and, on completion of the work, the nature of the repairs and date completed should he recorded, SECTION A.7: REPAIRS Leakage, broken parts, hard operation, and other major defects should be corrected by a repair crew as soon as possible after the defect is reported. If repairs are to be performed in the field, the repair erew should take a full complement of spare parts to the job site. Provisions should be made to isolate the defective valve from water pressure and relieve internal trapped pressure prior to performing any corrective maintenance. Disassembly of the valve should be accomplished in accordance with the procedure supplied by the manufacturer. After repair of the valve, the operatingy mechanism should be cyeled through one complete operating cycle. With full line pressure applied to the valve in the open 20016 Copyright American Water Works AssociationREDUCED-WALL, RESILIENTSEATED GATE VALVES 25 position, an inspection should be made to detect leakage in the areas around the seal plate, bonnet, packing gland, and body-end connections. A record should be made to indicate that the valve has been repaired and is in working condition. Any markings that the valvo is inoperable should be deleted. In addition, fire departments and other appropriate municipal departments should be informed of the satisfactory repair of the valve. 20014 Copyright American Water Works Association@ 1P-7.5M-43515-11/01-CM Printed on recycled paper 20014 Copyright American Water Works Association