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21.3

WATER OPERATION
YR3

no.116AND MAINTENANCE

UNIVERSITYOF CA RIVERSIDE, LIBRARY

BULLETIN NO . 116

3 1210 02503 5583

JUNE 1981

WATER RESOURCES
CENTER ARCHIVES

SEP 1981

Y OF CALIFORNIA

DERKELEY

IN THIS ISSUE

NEEDLE VALVES

UNITED STATES DEPARTMENT OF THE INTERIOR

Bureau of Reclamation
 WATER OPERATION AND MAINTENANCE
BULLETIN NO.116

June 1981

PREFACE

Water Operation and Maintenance Bulletin No. 116 is devoted exclusively to a presentation
of needle valves-the various types , problems , operating practices , and repair procedures .

Material for the article on needle valves was provided by E. O. Green , Mechanical Engineer
(retired), E& R Center; and Harvey J. Olberding , Foreman II , Maintenance , Black Canyon Field
Branch, Central Snake Projects Office . Special recognition is due to these dedicated Bureau
of Reclamation employees who blended the talents of design and construction with operation
and maintenance experience in developing the needle valve material for this special Water
O& M Bulletin . Mr. Lee Gerbig , Mechanical Engineer , E & R Center , assembled and edited
the drawings and figures used in the article .

The Water O & M Bulletin is published quarterly for the benefit of those operating
water-supply systems . Its principal purpose is to serve as a medium of exchanging operation
and maintenance information . It is hoped that the laborsaving devices and less costly
equipment developed by the resourceful water users will be a step toward commercial
development of equipment for use on irrigation projects in continued effort to reduce costs.
and increase operating efficiency.

Any information contained in this bulletin regarding commercial products may not be used
for advertisement or promotional purposes and is not to be construed as an endorsement
of any product or firm by the Bureau of Reclamation .

WATER RESOURCES
CENTER ARCHIVES
Division of Operation and
Maintenance Technical Services
SEP - 1981
Engineering and Research Center
Denver, Colorado 80225
UNIVERSITY OF CALIFORNIA
DERKELEY

In May of 1981 , the Secretary of the Interior

approved changing the Water and Power
Resources Service back to its former name , the
Bureau of Reclamation .

i
 CONTENTS

Page

PREFACE

INTRODUCTION 1

Scope . 1
General description of needle valves 1
Types of needle valves 2

Ensign (balanced) valve 2

Balanced needle valve • 3
Internal differential needle valve 7
Interior differential needle valve 19
Mechanically operated needle valve 25
Minatare Dam valve 25

OPERATION AND MAINTENANCE PROBLEMS 35

General 35
Drifting and sluggish operation 35
Sticking 36
Silt and trash • 38
Cavitation 38
Parts breakage 39

RECOMMENDED OPERATING PRACTICES 41

General 41
Exercising valves 41
Flushing valve interiors 41
Filling valve chambers 42
Unusual conditions 42

REPAIR PROCEDURES . . 44

Cleaning and descaling 44

Surfaces in sliding contact . 44
Paradox controls . . 46
550

Cavitation damage • 46
Welding
Repairing or replacing parts

!!!
 CONTENTS-Continued

FIGURES

Figure Page
722

Ensign (balanced) valve . 3

Drawing 4 - E-36 , general assembly of 58 -inch ensign
valve . 5
34

Balanced needle valve 7

4 Drawing 100- E- 105, general assembly of 60- inch.
balanced needle valve . 9
56

5 Internal differential needle valve . . 11

Drawing 45- D- 8022 , general assembly of 72 -inch
internal differential needle valve 13
7 Drawing 40- D- 600, operating instructions for internal
differential needle valve 15
8 Drawing 40 - D- 1090 , 4 - inch paradox control 17
9 Drawing 40- D- 418 , general assembly of 60 - inch internal
differential needle valve ... 21
10 Drawing 40- D- 492 , operating instructions for 60 -inch

223
internal differential needle valve · 23
12

Interior differential needle valve 25

12 Drawing 40- D- 2398 , general assembly of 54 -inch
interior differential needle valve 27
13 Drawing 40- D-2480 , field servicing and operating
instructions of interior differential needle valve 29
14 Drawing 40- D-2157 , assembly of 18-inch mechanically
operated needle valve . . . 31
15 Drawing 20 - E-229, Minatare Dam 24-inch needle
regulating valve 33
67

16 Removing needle-internal differential needle valve 37

17 Body extension after overhaul-interior differential needle
valve 37
18 Cavitation damage on needle-interior differential needle
valve 40
19 Drawing 32- D- 618 , modifications to nozzle
seats-60-inch balanced needle valves 47
20 Checking needle with template-internal differential
needle valve 49
21 Drawing 33- D- 3965, bull ring-60- inch balanced needle
333

valve 53

iv
 INTRODUCTION

Scope

Needle valves of various types have been installed on USBR ( Bureau of Reclamation ) projects
since the early days of the Bureau until the 1940's . All of these valves were designed by
the Bureau and are used as control valves to regulate flow from the reservoir through the
dam outlets .

The early type valve used until about 1920 was the " balanced valve " or more commonly
referred to as the " ensign valve . " The ensign valves were designed to be installed on the
upstream face of the dam at the entrance to the outlet conduits and were water hydraulically
operated .

The first of the line of valves referred to herein as needle valves was designed about 1920
and named " balanced needle valve . " Later designs are called " internal differential needle
valve " and " interior differential needle valve .'

The above three types of needle valves are water hydraulically operated . A few smaller sized
needle valves are mechanically screw operated . The needle valves are designed to be
installed on the downstream end of the outlet pipe and to discharge freely into a stilling.
basin or directly into the river.

The tube valve developed about 1940 is an outgrowth of the needle valve . It is essentially
a needle valve without the internal water chambers and with the needle shortened until it
is an open ended tube . The tube valves are mechanically screw or oil hydraulic operated .

The operating history of needle valves at various projects has been rated through a range
from good down to unreliable . In general , the higher the rating , the better the valve has
been maintained . But this is not always true as the water quality and other local conditions.
can significantly influence the amount of maintenance required on water-operated valves .
Needle valves do require more maintenance than other types of regulating gates and valves .
If needle valves are not well maintained , they will become unreliable .

Many years of operating and maintenance experience have been gained on needle valves .
It is important that the knowledge accumulated through the years be recorded for the benefit
of all present and future operating and maintenance personnel .

General Description of Needle Valves

Needle valves are constructed with their axis in line with the axis of the outlet pipes . The
working parts are in the center of the valve located along the axis and are attached to the
outer body by ribs . The body must be enlarged to form a water passage between the internal
parts and the body and then gradually reduced to the seat on the downstream end . The

1
movable control element is called a needle as the downstream end is tapered to a point.
The needle is held against the body seat to close off flow and is moved upstream to allow
flow . Water contained in chambers inside the valve and acting on plungers or pistons controls
the movement of the needle . Valving is provided to control the flow of water into and out
of the chambers . The valving is actuated by a control handwheel and by the movement of
the needle . When the handwheel is turned , the valving is actuated to produce needle
movement in the desired direction . The needle movement returns the valving to a neutral
position . In the neutral position , all forces in the valve chambers are balanced holding the
needle in this set position . If the needle drifts from the set position , the valving is actuated
to return the needle to position . The arrangement of the chambers is different in each type
.
of valve and there are even more variations of control valving but this general principal of
operation applies to all . Normally, reservoir water at existing reservoir head is used to
operate the needle valves.

The principals of operation and control are much the same for the ensign valve as for the
needle valves . The construction of the ensign valve is somewhat different as the body does
not contain a water passage as such . The main part of the valve is attached by ribbing to
a large downstream ring which is bolted to the upstream face of the dam . Water from the
reservoir flows through this ribbed area into the outlet conduit controlled by a movable
needle .

Materials used in the construction of the needle valves vary, but the following general
statements can be made : the bodies and the large structural parts were normally made of
cast iron , semisteel , or cast steel ; bronze was also used for some of the large castings ; and
bronze was normally used for seats , liners , bull rings , bushings , and other parts in sliding
contact.

Types of Needle Valves

Ensign (Balanced) Valve

Figure 1 is a diagram of the ensign valve showing the arrangement of the principal parts
and operating chambers . Figure 2 (drawing 4 - E - 36) shows the general assembly of a
58-inch ensign valve . The needle on this type valve was made as an integral part of a
cylindrical piston with a bull ring of larger diameter on the upstream end . The bull ring
fits into a stationary cylinder in which it moves laterally . Reservoir water acting directly
on the downstream face of the bull ring provides the opening force for the needle
assembly. Clearance was provided between the bull ring and the cylinder liner to allow
a limited flow of water past the bull ring into the upstream ( closing ) .chamber . A movable
control tube in conjunction with a poppet mounted on the needle provides control of water
flowing out of this chamber . As the tube is extended restricting flow, the needle is forced
downstream . As the tube is retracted , water flows out of the chambers faster than it comes
in and the needle moves upstream . With the tube held stationary, the needle remains in
position allowing water to flow out of the chamber at the same rate it comes in . Movement

2
 Opening chamber

Bull ring--

Body--
Piston
Needle

Opening

OW
chamber

FL
Cylinder

-Control line

Figure 1.- Ensign (balanced) valve .

of the control tube is provided by a handwheel through shafting , a gear set , and screw
drive . Some ensign valves were made without the control tube and can be used only in
the fully open or fully closed positions .

Balanced Needle Valve

Figure 3 is a diagram of the balanced needle valve showing the arrangement of the
principal parts and operating chambers . Figure 4 (drawing 100 - E- 105) shows the general
assembly of a 60- inch balanced needle valve . The needle on this type valve is attached
to a cylindrical piston with a bull ring of larger diameter on the upstream end . The valve
body is made large enough to receive this bull ring and is fitted on the inside surface with
a bronze liner. The bull ring fits closely in the cylindrical liner and moves laterally to impact
closing and opening travel to the needle . The downstream side of the bull ring is open.
to the valve waterway and subject to reservoir water pressure as long as the valve is
watered-up . (This arrangement is very similar to the ensign valve . ) The interior of the valve
body and the interior of the needle - piston assembly form one large water chamber (closing
chamber) . Water enters the closing chamber, both by leakage around the bull ring and
through a pitot valve located in the top splitter of the valve body. The pitot valve is
adjustable , but once adjusted is normally left in that position . Drainage from the closing
chambers passes through a control unit mounted on top of the needle valve . This unit is
fitted with two concentric sleeves . One sleeve is rotated by movement of the control
handwheel and the other by movement of the needle . Overlapping ports in these sleeves
control the flow of drainage water. When the handwheel sleeve is moved to increase

3
 A

HALF ELEVATION

O
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31 9-10

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15 T.
U. S. RECLAMATION SERVICE
F.H.NEWELL, DIRECTOR. A.P.DAVIS, CHIEF ENGR.
BOISE PROJECT
ARROWROCK DAM
58"BALANCE VALVE ASSEMBLY
QHENSIGN CHIEFELEG ENGR FEWEYMOUTH, SUPYENGR
PARTIAL SECTION AA Drown by 3-14 From Office of
VALVE CLOSED Traced U.S.Reclamation Serv
PARTIAL SECTION BB SHOWING PLAIN CONTROL CONNECTION Checked.coDSOFA LosAng eles,Cal -364
LEF -B Approved E Scale 1 Foot.

Figure 2.- Drawing 4 - E - 36 , general

assembly of 58- inch ensign valve.

5
4
Pilot valve

Flow Needle
Bull ring

Closing
Piston
chamber

Opening chamber
Body

Figure 3.-Balanced needle valve.

flow, the needle moves in the opening direction until movement of the needle-driven sleeve
causes flow in and out of the chamber to balance . In a like manner, opposite motion of
the handwheel controls the closing movement of the needle .

Some balanced needle valves are equipped with other types of control units . Two other
types will be mentioned here . In both of these , water is supplied to the interior chamber
only by designed - in leakage around the bull ring . On the valve at Pathfinder Dam , the
drainage water and the movement of the needle are controlled by a movable tube and
poppet arrangement mounted in the valve chamber . This control tube functions in like.
manner to the one for the ensign valve described above . On the valve at Buffalo Bill Dam ,
the flow of drainage water is controlled by an exterior poppet valve . The position of this
poppet is controlled by both a handwheel and movement of the needle through a shaft
and rack- and- pinon arrangement . In like manner to the sleeved control unit described
above, the poppet valve , by controlling the flow of drainage water, controls the opening
and closing movements of the needle .

Internal Differential Needle Valve

Figure 5 is a diagram of the internal differential needle valve showing the arrangement
of the principal parts and operating chambers.

7
་
 7
(58) 59 -Air vent for control vertical
(47)
(56)
69 Control (22)
(52)
(46)
34
60 (37)
(37)
(53) (57)
12 10 (24)
(61) (35) (48)

B.C12

iam
.

125½
12
(68
AIR VENTS WITH

"d
CONTROL HORIZONTAL (36) (66) (14)
-18-8 Stainless steel ring (41)

67)
5 (33)
(13) Chamber A
(38) (32)
49

(42)

'-5
" 4
(11) (44)

5-12
SECTION A-A

"diam
(9)

.72

64.000
3:3

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diam
4:69 (22)

87
(28)
(30) (29)
(43)

holes-
(40

.48-2
(16) (27)

BC
81
(10) (24) (23) (17)

78.100
Chamber

"Inside
7 B"

Dia-

"diam
(26)

78.575
78.550

.60
Valve
Ialve

diam
No.
VNo.
8

"&
"2
84
.
6 (39 60"BALANCED NEEDLE VALVE DRAWINGS
I Bill of Material
(45)
2 Layout Diagram
3 General Assembly
25% travel 4 Valve Body
5 Valve Nozzle
(18) 20 Piston Cylinder
(21) (19) 7 Piston, Piston Shoe & Needle
8 Piston Spider, Rack, Rack Spider,Etc.
9 Bull Ring, Nozzle Seat& Misc. Details

78.536

78.565
(36)

. am
10 Studs, Bolts & Wrenches

Valve

112
di
."Dia
10½" II Pitot Valve Control Quadrant, Etc.

No.
Flange & pipe for

Dia
Inner shell drain

Valve
I
Valve support

.
No.
furnished by U.S.

2
DEPARTMENT OF THE INTERIOR
2 BUREAU OF RECLAMATION
60"BALANCED NEEDLE VALVE
GENERAL ASSEMBLY
36
5:0 3) 010 SHEET 3 OF 16 DECEMBER, 1923
5-11- 2-8 4-38
-13'-2"
4 Valve drain piping CHIE ENGINEER
furnished bythe U.S.

Figure 4. -Drawing 100- E- 105 , general

assembly of 60- inch balanced needle
valve.

9
 Closing chamber-
Needle body \

HT FLOW

Head
Needle

Diaphragm

Opening
Diaphragm
chamber
tube

-Valve nozzle
INTERNAL DIFFERENTIAL NEEDLE VALVE

Figure 5.-Internal differential needle valve .

Figure 6 (drawing 45- D- 8022 ) shows the general assembly of a 72- inch internal differential
needle valve , and figure 7 (drawing 40 - D- 600) shows the operating instructions for this
type valve. The needle assembly on this type valve is provided with a long cylindrical body
which slides on a bronze liner and bronze guides in the valve nozzle . A head is attached
to the upstream end of the needle body. A diaphragm tube is attached to the valve body
and extends through a closely fitted opening in the needle head . A diaphragm is mounted
on the downstream end of the diaphragm tube and seals against the interior surface of
the needle body with a large piston ring . This arrangement creates three chambers in the
valve . The upstream and downstream chambers are interconnected and water pressure
in these chambers produces a closing force on the needle . Water pressure in the middle
chamber produces an opening force on the needle .

A paradox control , figure 8 (drawing 40- D - 1090), is normally provided on these valves
to direct water flow to and from the internal chambers . The paradox control is connected
to a water-supply line , to a drain line , and to the opening and closing chambers of the
valve . In today's parlance , it would be called servovalve . It is fitted with a removable
control piston (spool ) . Endwise movement of the piston is controlled by both the handwheel
on the control stand and through a rack-and - pinion arrangement on the needle . With the
piston at midpoint of travel , the water supply to the paradox control , the drain line, and
the waterlines to the needle valve chambers are all blocked creating a no-flow condition
and the needle is held in the set position . When the handwheel is turned , it moves the

11
 LIST OF PARTS -ONE VALVE
PART NO. DRAWING
NO. DESCRIPTION MATERIAL REQ'D. NUMBER
I Body Cast steel 1 45-D-8024
2 Nozzle Cast steel 45-D-8025
3 Needle quide Rolled bronze 8
4 Needle body Cast manganese bronze 45-D-8026
Cast steel 1 N

56
Needle tip 1 "
Needle tip ring Cast bronze
LIST OF DRAWINGS 7 Needle cone Cast steel I
8 Needle cone ring Cast bronze 1
VALVE 9 Control rack High-tensile cast bronze
GENERAL ASSEMBLY - LIST OF PARTS. 45-D-8022 10 Control tube Brass 1 "
LAYOUT DIAGRAM. 45- D-8023 Cast or rolled bronze "
BODY... Control tube plug 1
45-D-8024 12 Control spiderflange Cast steel
NOZZLE .45-D-8025 13 Cast steel
NEEDLE -CONTROL RACK- TUBE AND SPIDER 45-D- 8026 Control spider
PISTON RING - NOZZLE SEAT AND RETAINERS. 14 Piston ring Cast manganese bronze I 45-D-8027
45-D-8027 15 Ring retainer Cast manganese bronze 1
NEEDLE HEAD AND DIAPHRAGM 45-D-8028
DIAPHRAGM TUBE -CLAMP-TIP- CAP AND BEARINGS. 45-D-8029 16 Nozzle seat Cast bronze
UPPER AND LOWER UNIVERSAL JOINTS. 17 Seat retainer Cast steel I "
BOLTS-STUDS - SCREWS - STEMS- SHAFTS.. 45-D- 8030 18 Cast steel I 45-D-8028
45-D- 8031 Needle head
19 Diaphragm Caststeel 1
5* PARADOX CONTROL 20 Diaphragm tube Cast manganese bronze 45-D-8029
ASSEMBLY-LIST OF PARTS - DRAIN EQUIPMENT 45-D-8032 21 High-tensile cast bronze 2
CONTROL BODY... 45-D-8033 Clamp ring "
CONTROL BASE - COVER -LINER - PISTON. 22 Body tip Cast steel 1
45-D-8034 23 Cast bronze
CONTROL STAND - ELECTRIC OR MANUAL OPERATION Tip ring 1 "
24 Diaphragm tub cap Cast steel
ASSEMBLY - LIST OF PARTS. 45-D-8035 25 Control rack bearing Cast manganese bronze "
PEDESTAL AND COVER. 45-D-8036 26 Rack pinion bearing Cast manganese bronze /
GEARS. ..45- D- 8037 27 Cast bronze 45-D-8030
HANDWHEEL - LIMIT SWITCH PARTS- BUSHINGS-COLLARS. 45-D- 8038 Stem coupling 1
SHAFTING - SPRINGS - WASHERS AND BOLTS. 28 Stem fork Cast bronze
45-D- 8039 29 Upper stem fork Cast bronze 1 "
AIR VENT BREATHER MANIFOLD 30 Slip joint fork Cast bronze 1 "
ASSEMBLY-BODY - LIST OF PARTS. 45- D-8040 31 Body cap Semisteel 1 31
WRENCHES AND EQUIPMENT 45-D- 8041 32 Shaft fork Cast bronze 3
OPERATING INSTRUCTIONS 45-D- 8042 33 Slip joint fork Cast steel 1 "
ROCKING SOLE PLATE. 45-0-8043 34 Coupling nut Rolled bronze 2
35 Male coupling ring Cast bronze 2 "
36 Female coupling ring Cast bronze 2 "
37 Stem bearing Cast bronze 1
38 Shear pin carrier Steel 1 (2Halves) "
39 Cap gland Cast bronze I "
40 Control shaft gland Cast bronze 1 "1
41 Control rack pinion Forged copper- nickel alloy I 45-D-8031
42 Control shaft Cold finished steel 1
43 Stub control shaft Cold finished steel I "
44 Lower control shaft Forged copper-nickel alloy 1
45 Upper drive stem Seamless steel tubing 1 "1
46 Lower drive stem Seamless bronze tubing 1
47 Lower drive stem Seamless bronze tubing 1 B
CONTROL STAND- 48 Shaft fork pin Rolled bronze 2
49 Shaft fork pin Rolled bronze 4 "
50 Stem fork pin Rolled bronze 8
51 Needle cone plug Rolled bronze / "1
52 Special screw Bolt steel - class "C" 4
53 Tube shear pin Copper-See note on detail 12
54 Lock screw Boltsteel - class "A 2 M
55 Coupling nut lock Spring brass wire 2 21
¡Control stand 56 Coupling packing Garlock #26 or similar 4Rings #T
57 Shaft packing Garlock #26 or similar 4Rings
58 Shear pin Steel -See note on detail 12
--Operating floor 59 Shear pin bushing Tool steel 4 "1
60 Push-off bolt Rolled bronze 4 "1
Shims"

61 Jack bolt Boltsteel -class "C" 2

62 22"x13" Boltwith hex. nut Bolt steel -class "A" 64 "[
63 x 32" Stud with hex.nut Bolt steel - class "C" 4 "
Upper universal 64 1x 4 "Special bolt Bolf steel -class "A" 20 "
joint-- 65 12x32"Special bolt Bolt steel -class "A" 56 1
66 1"x5 " Hex. head tap bolt Bolt steel - class "A" 8 21
50 67 14"x Bolt steel -class "C" "
68 3""x 7"7""Hex.
Hex. head tap bolt
head tap bolt Boltsteel -class "C"
8
16 "
68 69 8"x3 " Stud with hex.nut Bolt steel -class "C" 4 R
70 1"x 4 "Stud with hex. nut Bolt steel - class "C" 16 "
71 1x 44" Stud with hex.nut Bolt steel-class "A" 22 17
72 24"x10 "Stud with hex.nut Bolt steel - class "A" 56 11
73 "x 22" Stud with slotted hex. nut Bolt steel -class "C" 4
NOTE 74 3"x4 "Stud with slotted hex.nut Boltsteel - class "C " 8 "
75 "x3 " Stud with slotted hex. nut Bolt steel -class "C" 4
All piping and fittings 76 14x5 "Stud with slotted hex.nut S.A.E. 2330 steel 56
42) shown in dotted lines 77 "
1x7 " Stud with slotted hex. nut Bolt steel - class "C" 16
arefurnished bythe 78 12"x 8 "Stud with slotted hex. nut S.A.E. 2330 steel 68 11
Government 79 ExI "Fillister head capscrew Rolled bronze 72
80 "x2 "Fillister head capscrew Rolled bronze 37 of
81 1"x1 " Fillister head capscrew Bolt steel- class "A" 16 11
NOTE AIR VENT 82 "Dia. round gasket Rubber (Solid) 33Ft. Ig. No detail
After assembling joints BREATHER MANIFOLD 83 " Dia. round gasket Rubber (Solid) 24Ft.lg.
thread wire thru holes 84 Dia. round gasket Rubber (Solid) 22Ft.lg.
in 50 and twist tight. 85 Dia.round gasket Rubber (Solid) 16 Ft. 1g.
86 "Dia. round gasket Rubber(Solid) 5Ft. 1q
87 Gasket # 28 gage (.0126) Soft copper I "1
88 ExFillister head capscrew Bronze 14 45-D-8031
Wrenches and equipment See Dwg 45- D- 8041
PCM

Lower universal 5" Paradox control -complete I Unit 45-D-8032

(28 Control stand - complete I Unit 45-D-8035
joint----- V Air vent breather manifold 1Unit 45-D-8040
(32) Rocking sole plate 1 Unit 45-D- 8043
Vent- Breather
-Vent
-11'-4"
(49)
(48)
2
(32
58 82
38
59 46
(69 83 (44 18 (84) 79 72
-37" 0 (66)
(+)

m()

(31) (16)
Dia."
135

18
(55 6
34 20
54 (23)
29
Dia
101":
assembly

SECTION THRU UPPER AND (80

Drawing

26
general

LOWER UNIVERSAL JOINTS 86

differential
Figure
8022
internal
needle
45
of
6.
-
valve
D-,

(25)
inch

Outlet-
72-.

Inlet
Dia.
86"-

Dia.
72"
DIFFERENTIAL

2943" Travel-
ASSEMBLY

alterations,
GENERAL

Designed
CHECKEPD

pressure
INTERNAL
TRACED

12-22-37 3-9-39
REV. 7-29-36 NG.W.
working
DRAWN

"Clearance
PARTS
27233

square

w.aw 1.2.A.
Needle
nozzle
NEEDLE
JEV
L.E.F

BOULDER
N.B.-

VALVE
LIST

inch
300
per
for

and
see
lbs.
TUNNEL

88
OF-
WORKS
PROJECT
OUTLET
BOULDER
DEPARTMENT
72"

CANYON
PLUG

12467
RECLAMATION
INTERIOR
DAM
RECOMMENDED

45
Barage

D-.
..SUBMITTED
DENVER,

NOTE
BUREAU
APPROVED.

76
13

MARCH

THE
yangu

OF
COLO.
1935
20,,

OF
...
.
SHEET
OF
10I
MateA.

Water pressure
supply line- -Drain line
r.
8022

5" PARADOX CONTROL

45
D-

Drain line.
 Y

30
0
Gage Cocks closed except when
Pressure Readings are desired.
12
NOTE Five Vent Faucets
Air Vent Stand and Piping
can be placed on opposite -VENT STAND--
side of Needle Valve from A" "B"
.Ports " E" to
that here shown. Chamber"B"
"F"
"D"

Pressure Gage.
Ports "F " from
Chamber "A"
Five Pressure to Chamber"C"
Gage Cocks.
Five Air Vents. Indicator Pressure Stand
Pointer- Pressure Stand
Valve Control Handwheel. <--Pipe Line --Pipe
Indicator Dial- Line
Indicator Dial

-ID-
PARADOX 10
-Vent Nozzles SECTION Y - Y Drain CONTROL
Header- KL
LY Drain Header--
--Air Vent Stand . DIAGRAM I DIAGRAM II
Cavity " D" Air Vent:: Brake' VALVE AND PIPING DIAGRAM SHOWING CORRECT
SECTION X - X VALVE AND PIPING DIAGRAM SHOWING CORRECT
2 Chamber "A" Air Vent:- Adjusting OPEN POSITION OF VALVES WHEN POSITION OF VALVES WHEN
Screw VALVE WIDE OPEN NEEDLE VALVE IS IN SERVICE
Control Stand:-- 3 Water Passage Air Vent:- PUTTING NEEDLE VALVE INTO SERVICE
4 Chamber" B" Air Vent:---
5- Chamber" C" Air Vent:-- -ID- OPERATING INSTRUCTONS
CLOSED Successful operation ofthe NeedleValve requires that the Pipe Line and the
InteriorValve Chambers"A", "B", and"C" and Cavity"D" be free from Trapped
--Indicator and Control Valve Stems Air and entirely filled with Water. Assume that Needle is in Closed Five Vent
Position and that Handwheel on Control Stand has been turned to the Right Faucets
Vent Stand Drain. Control Stand may as an alternative , asfaras itwill go.
be mounted directly on Needle Valve and SLIGHTLY OPEN TO PUT VALVE INTO SERVICE. ( See Diagram I ) Open Five Air Vent Faucets ( 12) VENT
-the Extension Stems here shown omitted . onVent Stand, Close Valves (6), (7), (8), (9) and (10)in Lines beneath NeedleValve, STAND
then SlowlyOpen Valve (11) part way in PressureSupply Line, thus allowing the
VALVE SYMBOLS InteriorValve Chambers to Slowly Fill.CloseVent Faucets (12)in Lines (2) and (5) in turn
after eachis discharging a SteadyStream . Fill Pipe LineSlowly, preferablyUsing By-pass
for EmergencyGate, and when AirVent Faucet (12) in Water Passage Line (3) is Discharg-
ingsteadily it may then be closed . Handwheel on Control Stand should nowbe turned
Water veryslowlyto the Left, therebyFillingCavity"D"and Chamber" B"and as soon asAirVent
O PIPE LINE- Faucets (12)in Lines (1 )and (4)are dischargingsteadily, theseValves should be Closed.
O

O Passage.
O All Valves should now be in the Relative Positions shown by Diagram II and theNeedle
O Valve is now ready for Service.
O

TO OPEN VALVE. Turn Handwheel on Control Stand to theLeft, slowly,followingup

-Needle
O
O

theNeedle's movement until the Indicator Pointer on Control Stand registers the
O

"A" "C"
openingdesired.The Speed ofthe Needlesmovementmay be Regulated bytherate
о

of Handwheel movement and by varying the Flow in PressureSupply Line byAdjustment Stand
O
O

ofValve (11). Pressure --- Pipe

Line
O о O

Ports " E" TO CLOSE VALVE. Turn Handwheel on Control Stand to the Right.
"D" TO PUT VALVE OUT OF SERVICE AT END OF SEASON . First Close Needle Drain 10
Header
--Port"F" X Valve, thenClose Emergency Gate in PipeLine and CloseValve (11)in Pressure Supply
Line.All otherValves in Vent and Drain Systems,including Pipe Line DrainValve ,
shouldnow be opened wide.The Relative Positions oftheValves should now be DIAGRAM III
in accordance withDiagram III . permittingfree drainage oftheValves Interior, VALVE AND PIPING DIAGRAM SHOWING CORRECT
POSITION OF VALVES WHEN
thereby avoiding any danger due to Freezing. NEEDLE VALVE IS TAKEN OUT OF SERVICE
O
GENERAL INSTRUCTIONS
O

Water The Inside ofthe Valve should be examined once a year, all Pipes and Ducts
O

Passage. inspected to insure thatthey are Open, and any Scale that may have formed
Valve Chamber on Finished Bronze Surfaces should be removed. When theValve is being
--Standpipe. DEPARTMENT OF THE INTERIOR
operated at Partial Openings forlong periods,anytendency ofthe Needle to creep BUREAU OF RECLAMATION
Pipe Line Drain- 10 from its desired position can be corrected byturning theBrakeAdjustingScrew, INTERNAL DIFFERENTIAL NEEDLE VALVES
Standpipe beneaththeTop ofControl Stand, afraction ofaturn to the Right . The Needle
11 Chamber C Drain- Valve ofthisValve may be moved at will either open,or closed, or to Intermediate DIRECT BOTTOM PARADOX CONTROL
PARADOX ICI
Ol HD CONTROL Pressure Supply to -Chamber B Drain -Drain Positions,while the Pipe Lineis empty, through the agencyofthe Pressure OPERATING INSTRUCTIONS
PARADOX CONTROL PARADOX Header
Control Exhaust CONTROL ParadoxControl Drain- 8 SupplyLine and the Paradox Control. Standpipe Valve (10) should be kept
Line Air Vent Drain- closed exceptwhen the Reservoir Water Surface has fallen so Low that the DRAWN: P.A.K.. SUBMITTED :. 6.MyDay..
Needle does not respond to the Controls, in which event only should Valve TRACED : AAA. RECOMMENDED:... JhJarage
"Water Passage Drain<-9 CHECKED :.. APPROVED: Halter .
VALVE CLOSED (10) be opened while Needle Valve is in Service.
INLET LONGITUDINAL SECTION DENVER, COLO., JUNE. 2.1930 40-D-600
END VIEW

Figure 7. -Drawing 40- D- 600, operating instructions for

internal differential needle valve .

15
 HALF PLAN
PI HALF BOTTOM VIEW
(P16
(P2)
HALF SECTION D- D
(P5) P6) (PIT) PIT
(PIT) Ө P4

O
A

P4 PI

(P16

LIST OF PARTS - ONE PARADOX CONTROL

PART MATERIAL NO. DWG.
DESCRIPTION REQD NO.
HALF SECTION C- C HALF SECTION E-E HALF SECTION F-F NO. 1 40-D-1091
B PI Control body Semisteel
P2 Control base Semisteel I 40-0-1092
P3 Control cover Semisteel I "
(P19) "to end of P4 Control liner Cast manganese bronze 1
drive stem P5 Control piston Cast manganese bronze 1 "I
(P2) P2 P6 Control screw Cast high tensile bronze "
A P7 Control spider Cast high tensile bronze I "
"

control
P8 Control nut Cast bronze
shaft-
P16 "1
P9 Control screw bonnet Rolled bronze
P14 end
of
"to
13 PIO Control screw collar Rolled bronze I
P13 P20 I "
PII Screw collar lock Spring brass wire
Y P12 Thrust washer Brass 2 "1
(P4 PI3 Control nut collar Rolled bronze 1
P14 Nut collar lock Spring brass wire 1 M
(P5 Rolled bronze 2
PI P15 Ball seat
NOTES Bolt steel- class "A" 40 "
P8 Provide 0.008" end play at X and Y P16x3"Stud with nut
PIT "x2 "Stud with nut Bolt steel - class "A" 16
with parts assembled as shown P18 One inch dia. ball Copper nickel alloy No detail
Designed for 100 lbs. per square inch P19 Gasket I 11
working pressure Soft copper No. 28 gage
P20 Gasket Soft copper No. 28 gage
Lo

P21 Gasket Soft copper No. 28 gage

www.moth Travel--
‫نا‬

REFERENCE DRAWINGS DEPARTMENT OF THE INTERIOR

NOTE 60" INTERIOR DIFFERENTIAL NEEDLE VALVE .....40 - D -1080 BUREAU OF RECLAMATION
P18 P15 Position of piston P5 as shown 54"INTERIOR DIFFERENTIAL NEEDLE VALVE..... DENVER OFFICE
P16) is for control in full opening INTERIOR DIFFERENTIAL NEEDLE VALVE
position. 4" PARADOX CONTROL
P3 ASSEMBLY -LIST OF PARTS
B DRAWN. L.E.F- J.W.T SUBMITTED CMDay.
TRACED . J.D.-J.EV RECOMMENDED.itholder .

. -25-36
SECTION B- B CHECKED .. J.P.. APPROVED. 9.I Walter.
SECTION A - A

8REV
27965 DENVER,COLO. I OF 3 , 1935 40- D- 1090
SHEET JULY

Figure 8. - Drawing 40- D- 1090 , assembly of 4- inch

paradox control.

17
paradox control piston one direction for " open " and the other for " close . " This directs
water supply to the proper chamber(s) and connects the other chamber(s ) to drain producing
the desired movement of the needle . As the needle moves , it restores the piston to
midtravel stopping both water flow and needle movement . In like manner, if the needle
drifts out of position , the paradox control piston is moved producing a flow of water to
restore the needle to position .

An internal differential needle valve using a control spear rather than a paradox control
is shown in figure 9 (drawing 40 - D - 418 ) . Figure 10 (drawing 40 - D - 492) shows the operating
instructions for this valve . In this type valve , water at reservoir pressure is present in the
opening chamber at all times when the valve is watered - up . A controlled flow of water
enters the closing chambers through a built - in clearance between the needle body and
the nozzle bushing . A controlled flow of drain water exits the closing chambers through
an opening in the center of the needle tip . Flow of the drain is controlled by a spear running
through the center of the valve and seating in the needle tip opening . The spear is
connected to the control handwheel through a rack and pinion . Turning the handwheel
produces lengthwise movement of the spear . Downstream movement of the spear restricts
drainage from the closing chambers and increases the water pressure . Upstream movement
of the spear increases drainage producing a drop in water pressure in the closing
chambers. Since there are two closing chambers and one opening chamber, and reservoir
pressure is always present in the opening chamber, the pressure change produced by
movement of the spear results in a needle movement in the same direction as the spear.

Interior Differential Needle Valve

Figure 11 is a diagram of the interior differential needle valve showing the arrangement
of the principal parts and operating chambers .

Figure 12 (drawing 40 - D- 2398 ) shows the general assembly of a 54 - inch interior differential
needle valve and figure 13 (drawing 40 - D- 2480) shows the field servicing and operating
instructions for this type valve . The physical arrangement of this valve is somewhat different
than the internal differential needle valve but the internal chamber arrangement is similar.
The needle body on this valve is exterior tothe body extension and is attached to a
diaphragm tube with an integral diaphragm on the upstream end . This diaphragm slides
on and seals against a liner on the inside of the body extension . The body extension has
an integral diaphragm on the downstream end which seals against a bronze sleeve on
the exterior of the diaphragm tube . This arrangement forms the three internal chambers .
Water pressure in the interconnected upstream and downstream chambers produces a
closing force on the needle and produces an opening force in the middle chamber. This
valve is equipped with a paradox control that functions in the same manner as the paradox
control described above for the internal differential needle valve .

19
 LIST OF PARTS - ONE VALVE LIST OF PARTS CONTINUED 60" Dia. Outlet-
PART MATERIAL NUMBER DRAWING PART DESCRIPTION MATERIAL NUMBER DRAWING
NUMBER DESCRIPTION REQUIRED NUMBER NUMBER REQUIRED NUMBER
Semisteel 40-D- 425 39 Control Wheel Semisteel / 40 -D-431

rpacking
/ Long Body

1-toquare
graphite
changed
/ 40-D-427 40 Control Wheel Washer Mild Steel 1

ound
Packing
2 Nozzle Semisteel and Bronze
V Special Gear Bronze /

"and
s5-32
52
8 41 Indicator Pinion

from
3 Needle Guide Rolled Bronze

flax
4 Seat Retainer Cast Steel
5 Needle Cast Manganese Bronze 1 40-D-428

Fittings
Dotted
Piping
shown
6 Needle Tip Semisteel and Bronze 1

Lines
Government
Bolt Steel - Class "A" 3 40-D- 432

packing

and
Bronze / 45 3/8"x1 " Tap Bolt

All
Garlock
.7 Needle Ring

rubber

in
<

furnished
8 Mild Steel 46 1/2"x1" Tap Bolt Bolt Steel - Class "A" 1
Packing Clamp

69
9 Nozzle Seat Cast Manganese Bronze / Y " 47 5/8"x 28" Tap Bolt Bolt Steel - Class "A"
Bolt Steel - Class "A"

will
Indicator Rack High Tensile Bronze 1 48 3/4"x13/4" Tap Bolt

the
10

.by
be
11 Control Spear Brass 1 49 3/4" x 2" Tap Bolt Bolt Steel - Class "A" 10

12
50 Bolt Steel - Class "A" 12

)(65
12 Needle Head Semisteel and Bronze 40-D-429 3/4"x22" Tap Bolt
13 Semisteel / 51 3/4"x32" Tap Bolt Bolt Steel - Class "A" 3
Diaphragm Bolt Steel - Class "A" 8
52

NOTE
14 Control Spider Semisteeland Bronze / 3/4"x33/4" Tap Bolt
15 Outlet Head Semisteel 53 1"x5/ 2" Tap Bolt Bolt Steel - Class "A" 8
CastManganese Bronze / 40-D- 430 55 5/8"x3" Stud with Nut Bolt Steel - Class "A" 24
16 Diaphragm Tube BoltSteel - CI. "A"-Bronze Nut 14
17 Diaphragm Clamp CastManganese Bronze / 56 5/8"x32"-Stud with Nut
18 Vent and Drain Manifold Cast Manganese Bronze 57 1/2"x 7" Stud with Nut Bolt Steel Class "A" 56
Tube Cover CastManganese Bronze 1 58 1/2"x1/ 2" Fillister Hd. Cap Screw Bolt Steel Class "A" 9
19 Rolled Bronze 72
20 Control Crosshead CastManganese Bronze 1 59 9/16"x1/4"Fillister Hd. Cap Screw
Crosshead Nut CastManganese Bronze / 60 7/8"x23/4"Fillister Hd.Cap Screw Bolt Steel Class "A" 36 はこつ
21 72
22 Control Shaft High Tensile Bronze / 40-D-431 61 7/8"x48"Stud-Castellated Nut Bolt Steel Class "A"
23 Indicator Shaft HighTensile Bronze / 62 1/2"x5/8" Stud- Castellated Nut Bolt Steel Class "A" 22

4-9
4 63 1/4"x144"Bolt -Castellated Nut Bolt Steel Class "A" 2
24 Manifold Pipe Standard Brass Pipe

72
"
Spring Brass Wire 3 " 64 2"x 83/4" Bolt - Castellated Nut Bolt Steel Class "A" 60
25 Locking Ring Bolt Steel Class "C" /
26 Control Bevel Pinion Special Gear Bronze 65 3/8"x1 " Flat Head Cap Screw
Control Bevel Gear Special Gear Bronze 66 /2"x14" Flat Head Cap Screw Bolt Steel Class "C" 12
27

Header
Standard Forged Steel See Note Clearance

3"Drain
28 Rack Pinion Special Gear Bronze 67 2" Eye Bolt
Mild Steel 3 68 Ring Packing Garlock No.99orequal 3/8"Sq. 20 Rings 113" Dia.
29 Gear Nut

---
--------
Steel See Note

"ravel
Semisteel 69 23/4" Spanner Wrench

T-2-18
30 Control Head See Note
Speed Control Valve Bronze / 70 3/4" Spanner Wrench Steel
31

'-3
▼

" 9
71 Crosshead NutWrench Cast Steel See Note 5
32 Speed Control Valve Nut Bronze See Note No Detail

237
/ Diaphragm Packing Garlock Rubber Packing
33 Speed ControlValve Seat Bronze Rubber 20 ft.long No Detail
34 Valve Nut Collar Bronze / 14" Round Gasket
Bronze 7 74 1/2"Round Gasket Rubber 24ft. long No Detail
35 Gland
36 Indicator Pointer Brass
37 Lock Nut Steel /
38 Thrust Washer Bronze /
Note:-Furnish one each of Parts 67-69-70 and 71 for each Item ofContract
regardless of the number of Valves Specified.

4-6

)(29
"
LIST OF DRAWINGS

62
VALVE 1 LONG BODY TYPE - STAND CONTROL

JOT
GENERAL ASSEMBLY - LIST OF PARTS.. 40- D-418

D" rains
40-D-422 IXII
CONTROL ASSEMBLY - GEARS - COUPLINGS..
LAYOUT DIAGRAM AND VELOCITY CURVE.. 40- D-423 Ա ՄՆ-
LONG BODY.... 40-D-425 57145
||XIII

(22
NOZZLE AND SEAT RETAINER. 40-D-427
NEEDLE - NOZZLE SEAT-PACKING CLAMP. 40-D-428
NEEDLE HEAD -DIAPHRAGM - CONTROL SPIDER 40- D-429 IIXII
55
CONTROL
STAND-

DIAPHRAGM TUBE AND CLAMP - MANIFOLD. .40- D-430

5

89(
CONTROL HEAD SHAFTS AND GEARS. 40-D-431

Ol
BOLTS STUDS - SCREWS- WRENCHS.. 40-D-432
STAND

V"lents
VENT
TEST

VENT STAND
Operating

циал .....
ASSEMBLY- LIST OF PARTS -DETAILS. 40-D-433
Floor

CONTROL STAND

Header
ASSEMBLY-LIST OF PARTS- GEARS. 40- D-434
...

PEDESTAL -COVER -EXTENSION STEMS. .40-D-435 Drain

" ipe
Pto
3

DEPARTMENT OF THE INTERIOR

BUREAU OF RECLAMATION
DENVER OFFICE
93

72" Dia. Inlet

)(92

60" INTERNAL DIFFERENTIAL NEEDLE VALVE

LONG BODY TYPE - STAND CONTROL
GENERAL ASSEMBLY -LIST OF PARTS
====

REV.10-1-32
75

DRAWN: PAK. SUBMITTED:.. c.m. Day

TRACED: J.J.S.
CHECKED: P.B. RECOMMENDED:
APPROVED: J. Walt adage
er .
-"H" (See Specifications) JUNE, 1928 40- D-418
23451 DENVER, COLO.,
SHEET OF 10

Figure 9. -Drawing 40 - D- 418 , general assembly of

60-inch internal differential needle valve.

21
 NOTE Fixed
Gage Cocks closed except when
Pressure Ports "E" "A" Diaphragm "C" Pressure Reading is desired 12
AirVent Stand and Piping to Chamber "B" "B"
can be placed on opposite Five Vent Faucets-.
side of NeedleValve from

ID
that here shown . VENT STAND
"D"
Speed Control Valve- Speed Control Valve
(See Instructions) (See Instructions),

17
Pressure Gage Equalizer;
Ports "F"/ Packing
between Clamp 2 To Drain Header 13 2 To Drain Header
SECTION Y-Y Chambers
Five Pressure "A" and "C" OPEN
Gage Cocks Speed Valve Control
Valve Control Handwheel NEEDLE VALVE NEEDLE VALVE
Five Air Vents Indicator Pointer
nar
Packing
Vent Nozzles --Indicator Dial -D- Pressure Pressure
Line Line
Chamber " C" Air Vent- CLOSED
-Air Vent Stand
Chamber " B " Air Vent-
3-Cavity " D " Air Vent- 10
4 Chamber " A " Air Vent- Drain.
-Control Stand SECTION X - X Ejector Header Ejector
5-WaterPassage Air Vent- VALVE WIDE OPEN
SLIGHTLY OPEN DIAGRAM I DIAGRAM II
-Filler Pipe VALVE AND PIPING DIAGRAM SHOWING CORRECT VALVE AND PIPING DIAGRAM SHOWING CORRECT
--Control , Indicator and Speed Valve Stems VALVE SYMBOLS POSITION OF VALVES WHEN POSITION OF VALVES WHEN
PUTTING NEEDLE VALVE INTO SERVICE NEEDLE VALVE IS IN SERVICE
Vent Stand Drain Control Stand may as an alternative , be
mounted on the Operating Floor andthe
"A" and "D" AirVents Steel Support here shown omitted . OPERATING INSTRUCTIONS
WaterPassage Speed Control Valve-
AirVent -Control Head Successful operation ofthe NeedleValve requires that the Pipe Line and
the InteriorValve Chambers"A""B"and"C"befree from TrappedAirandentirely 12
filled with water. Speed Control -Five Vent
Valve
Assume Plunger in Closed Position, Speed ControlValve, Control Spear andall (SeeInstructions) Faucets
O O Water Passage SmallValves in Control Piping closed . It is ESSENTIAL that Chambers "A"
PIPE LINE VENT
and "C" be Vented in advance of Chamber "B"to prevent Plungerfrom moving
Speed' open before the Valve is ready for operation. STAND
O

O
о

Valve TO PUT VALVE INTO SERVICE ( Refer to Diagram I ) Fill Pipe Line slowly,
C
O

2 Inlet "A" "C" Needle preferablyusing By-passfor Emergency Gate . Open all VentFaucets (12)at
O
O

Chamber "B"- 2 VentStand.When PipeLine and WaterPassage are filled, closeWaterPassage

AirVentLine AirVentfrom . AirVent from AirVentValve (5) and openValve ( 13) in Filler Pipe to fill Chambers "A"and "C" O 2 To Drain Header
O

Chamber "C" Chamber"B"

which areVented by( 1 ) and (4), and Valves (6) and (7 ) in Ejector Lineto force
O

Indicator Shaft Air out of Siphon Drains (15) and (16)

Port "E"
When Chambers"A"and "C"and their Siphon Drains are filled with Waterclose NEEDLE VALVE
"D" Faucets in Vents (1 ) and (4) and Valves (6),(7) and (13),open SpeedControl Valve
Indicator Spider- X about 1/4 turn, using a wrench on the Squared End oftheStem on theOperating Pressure
X
OO

L
-
Stand,then when Chamber "B "is filled with WaterClose Faucets (2) and (3). Line
Port "E"
7 Control When a FullStream ofWater is runningfrom the Faucets the CavitiestheyVent ID
6 Siphon Drain from Spear arefreefrom Air and full ofWater.The NeedleValve is nowreadyfor Opening.
Siphon Drain from Chamber" C" (16 Referto Diagram II to insure that all Control Valves are in Proper Position.
O Chamber"B" (15) TO OPENTHE VALVE Turn Valve Control Handwheel on Operating Stand Drain
Chamber"C" Slowlytothe Left until the Indicator shows the desired Opening. Header Ejector
O

0 0 AirVent Line TO CLOSE THE VALVE TurnValveControl Handwheel to the Right.TheSpeed

DIAGRAM
O

ofthe Needle Movement may be controlled bythe Speed Control Valve,and Final
O Water Passage VALVE AND PIPING DIAGRAM SHOWING CORRECT
Adjustment can now bemade to suit conditions of Operation.
TO PUT VALVE OUT OF SERVICE AT END OF SEASON First Close POSITION OF VALVES WHEN
NEEDLE VALVE IS TAKEN OUT OF SERVICE
Connect to any Pipe Line having Full NeedleValve,then Close Emergency Gate in the PipeLine, and Open Pipe Drain
-Air Vents Reservoir Pressure,for use in starting Valve.Open AllValves in Control Pipe System as shown in Diagram III except
B" and "C" Pipe Line Drain Needle from Full Open Position. Valves (6) and (7) . Open Valve (8 ) in Pressure Line thus putting Ejector intoService.
8 Then OpenValve (7)leave itthusfor afewminutes,thenClose it and OpenValve (6).
Pressure Supply toWater Ejector --t -Water Passage Drain Alternate thus until Chambers"B"and "C"arefree ofWaterandall Pipesare Empty.thus DEPARTMENT OF THE INTERIOR
Chamber "A" Drain 10 BUREAU OF RECLAMATION
Water Ejector--- avoidingDangerofFreezing.AllValves should be leftasshown in DiagramIII until readyto
--Water Ejector AirVent Stand Drain---- Cavity " D " Drain-9
put NeedleValve in Service again. 60"INTERNAL DIFFERENTIAL NEEDLE VALVE
-Drain Header GENERALINSTRUCTIONS SomeLeakage is ESSENTIALbetweenChambers"B"and"C"
6 and 7 pastthePackingaround the Rim ofthe Fixed Diaphragm insidetheNeedle.Forthisreason the OPERATING INSTRUCTIONS
Ejector Suction Line Siphon Drain from Chamber "C"-
"B" PackingRingshould notbedrawn sotightly againstthePacking asto preventa smallamount of
Siphon Drains " B" and "C " Leakage,orto cause the PackingtoBindwhentheNeedleMoves,asthiswillmakethe NeedleSluggish
-Air Vent Drain - Chamber " B " 2 DRAWN : PA.K. SUBMITTED:.. C.Mr.Gay..
"C" inOperation,andmay causeitto stick,and thenmove suddenlywithDangerof DamagingtheValve. TRACED:A-A.A RECOMMENDED:.
INLET - END VIEW The Inside oftheValveshould beexamined onceayear,all Ducts and Pipes checkedto insurethat KED
CHEC : ROM APPROVED:.... Walter
LONGITUDINAL SECTION VALVE CLOSED theyare notStopped, andanyScalethatmayhaveFormedon FinishedBronzeSurfacesshouldbe removed. DENVER COLO., JAN . 22.1929 40- D-492

Figure 10.- Drawing 40- D-492, operating instructions for

60-inch internal differential needle valve.

23
 Closing chamber

FLOW

Needle

Opening
chamber
立

Diaphragm tube

Body
extension

Body - -Needle body

INTERIOR DIFFERENTIAL NEEDLE VALVE

Figure 11.-Interior differential needle valve .

Mechanically Operated Needle Valve

Figure 14 (drawing 40- D- 2157 ) shows the assembly of an 18 -inch mechanically operated
needle valve . Operation of this valve is straightforward . The needle is driven by a screw
located on the centerline of the valve . The screw is driven by a handwheel on top of the
valve through a set of bevel gears . A drain is connected to the interior chamber of the
valve to dispose of any leakage water .

Minatare Dam Valve

The 24-inch needle regulating valves at Minatare Dam are a " one - of-a - kind '' type built
about 1922. The assembly of these valves is shown on figure 15 (drawing 20 - E - 229) .
Contrary to the general rule for needle valves , the needle and operating mechanism for
this valve are at a right angle to the incoming flow . The needle and discharge nozzle are
on one side of the body and the mechanical screw type operator is on the other side .
A stem is attached to the needle and passes through the body to the operator. A piston
is attached to the stem on the operator side to balance the hydraulic load on the needle.

25
 LIST OF PARTS - ONE VALVE
LIST OF DRAWINGS
PART MATERIAL NUMBER DRAWING
VALVE DESCRIPTION REQD. NUMBER
GENERAL ASSEMBLY - LIST OF PARTS. 40- D- 2398 NUMBER 40-0-2400
LAYOUT DIAGRAM. 40- D- 2399 I Body Semisteel
40 - D- 2400 Semisteel 40-D-2402

234561
BODY... Body extension TT
BODY SECTIONS. 40 - D- 2401 Body tip Semisteel 1
BODY EXTENSION - BODY TIP_. 40 - D- 2402 4 Body tip ring Cast bronze I
NEEDLE - CONTROL RACK CLAMP RING. 40- D- 2403 Semisteel 1 40-0-2403
DIAPHRAGM TUBE. 40- D - 2404 Needle body TE
PISTON RINGS NOZZLE SEAT - RETAINERS 40 -D- 2405 Needle tip Nickel cast iron I
7 Cast bronze I 77
OUTLET FLANGERING RETAINER BUSHING. 40 - D- 2406 Needle tip ring
BOLTS STUDS - MISCELLANEOUS PARTS. 40- D -2407 8 Control rack High tensile cast bronze
9 High tensile cast bronze 1 TT
4" PARADOX CONTROL Clamp ring 40-D-2404
10 Diaphragm tube Nickel cast iron
ASSEMBLY -LIST OF PARTS... 40- D- 1090 Nozzle seat Cast bronze 40-0-2405
CONTROL BODY... 40 - D-1091 Cast steel TT
CONTROL BASE COVER LINER PISTON. 40 - D- 1092 12 Seat retainer
13 Piston ring Cast manganese bronze I
14 Cast manganese bronze I TT
CONTROL STAND- DIRECT OR EXTENDED Piston ring TT
ASSEMBLY GEARS - LIST OF PARTS. 40-D- 729 15 Ring retainer Cast manganese bronze
PEDESTAL AND COVER - SHAFT- STEM - COUPLINGS.....40-D - 730 16 Outlet flange Cast steel 1 40-0-2406
17 Ring retainer Cast manganese bronze I 77
I"AIR VENT MANIFOLD 18 Rolled bronze 2
ASSEMBLY - BODY - LIST OF PARTS. 40-D-962 Rack pinion bearing. TT
19 Body cap Semisteel TT
40- D- 2408 20 Body tip bushing Cast bronze I
WRENCHES AND EQUIPMENT 1 40-0-2407
ERECTION GUIDES.. 40-D- 2409 21 Control rack pinion Rolled copper- nickel alloy TT
22 Indicator stem coupling Cast bronze I
SHOP TESTING SET UP AND INSTRUCTIONS. 40- D- 964 1 ..
23 Coupling nut Rolled bronze
OPERATING INSTRUCTIONS (TO FIT EACH INSTALLATION) 24 Coupling nut lock Spring brass wire I
2

567
25 Drive stem Seamless bronze tubing TT
26 Control shaft Rolled copper-nickel alloy I
27 Control shaft gland Cast bronze 1
28 Shaft packing For water 1-Set
29 For water 1- Set TT
Coupling packing_ I TT
30 Cap gland Cast bronze
31 Steel 2- Halves
Shear pin carrier 4
32 Shear pin bushing S.A.E. 6140 or 6145 steel TT

26
33 Shear pin Steel 12
34 Lock pin Bolt steel - class "A" 36 TT
35 Lock screw Bolt steel - class "A" 77
36 Rolled bronze 2
© Special screw 4
37 Plug Rolled bronze TT
CONTROL STAND 38 Flat head capscrew Rolled bronze 8
39 2x12" 8 TT
DIRECT OR EXTENDED. 711 Fillister head capscrew Rolled bronze 77
40 x2 3 T Fillister head capscrew Bolt steel - class "A" 16
41 16 TT
x2 Fillister head capscrew Bolt steel - class "A" TT
42 4x32 Tap bolt Bolt steel 4
43 x32 Tap bolt Bolt steel - class "A" 8
44 2 x54"
C3 Tap bolt with nut Rolled bronze 8 77
45 x34" Stud with nut Bolt steel 4
46 2x34" Stud with nut Bolt steel - class "A" 22 TT
47 2x58 Stud with nut Bolt steel- class "A" 12 77
Operating floor- Shims
16 TT
48 14x9 Stud with nut Bolt steel - class "A"
49 1x Stud with nut Bolt steel - class "A" 48 TT
50 x2 Stud with castle nut Bolt steel - class "A" 8 17

86
77

45 69
51 3 x34 Stud with castle nut Bolt steel - class "A" 48
I" AIR VENT 52 3x3 Stud with castle nut Bolt steel - class "A" 56 TT
MANIFOLD 53 1"x42" Stud with castle nut Bolt steel - class "A" 46
NOTES 54 2" Dia. round gasket Solid rubber 18 Ft. Iq. No detail
55 Dia. round gasket Solid rubber 14Ft. 1g. No detail
All piping and fittings 56 No detail
shown in dotted Gasket- No. 28 gage (0.0126") Soft copper 16" 0. D.
lines are furnished
CPYE

by the Government. See Dwg

For dimension "H", see Wrenches and equipment
Control stand - complete 1-Unit 40-D-729
specifications. 4"Paradox control - complete 1-Unit 40-D-1090
33 -I" Vents 1-Unit 40-D-962
V 1"Air vent manifold
Erection quides 1-Unit 40-D-2409
H
"

1" Vent- (28)

7'-6"-
47
19

24
124
54
55
34 (13) 49
2383" (43)

12
-3

23"Travel
94"'-

outlet
Dia.
-54"
50

38 34
inlet
Dia.
-66"
B.C.

Dia
Dia.

B.C.
-76"

-83."
-80"

Dia.
80"

-90"

(20
50

18
3-9"

26 14
Ө
assembly
Drawing
general
differential
Figure
2398
interior
12.
needle
of
40
D
valve
--,
inch
54-

DIFFERENTIA

2-72"
ASSEMBLY
SUBMITTED

INTERIOR
GENERAL
CHECPIK
TRACE
W.M.SD. in
28756

NEEDLE
T.-L.E.F.
DRAWN
PARTS
VALVE
KED

LIST
W.
J.

54
OF-

DEPARTMENT
L
"

RECLAMATION

--95"

(46)
INTERIOR
RECOMME

-22" Drain line

BUREAU
DENVER,
APPROVED.

THE
OF
du

DENVER
27

COLO.

OFFICE
OF
SHEET

NDED
Sot
OF
10

4" Pressure -4" PARADOX CONTROL

arpis

supply line
OCT.
1936
16,

daung.

Jack bolt
13"
.

4"Drain line-
2398
40-

DESIGNED FOR 100 LBS . PER SQUARE INCH WORKING PRESSURE

D-
 OPERATING INSTRUCTIONS
IMPORTANT IV TO PUT VALVE INTO SERVICE WHEN THE NEEDLE IS IN INTERMEDIATE
I PRE - SERVICING INFORMATION :
FOR SEMINOE DAM ONLY - The needle valves A. The Needle can only be moved hydraulically by pressure introduced into chambers POSITION:
shall not be operated when the elevation of the A and A' or B through the pressure supply line and the Paradox Control . A. Rotate handwheel on Control Stand in a clockwise direction as far as it will go.
tail water is higher than 6142.5 B. The function of the handwheel on the Control Stand is to operate the Paradox B. Close valves 3 and 5 , open valve I about one - fourth and fully open valves
Control. There is no mechanical connection between the handwheel on the Control 2 and 4.
Stand and the Needle ; therefore , do not attempt to move Needle by twisting the C Follow any movement of the Needle which may occur with further rotation of
handwheel if the valve is not serviced or if the Needle sticks during operation . the handwheel and watch valve 4 , When water begins to flow from valve 4 ,
C. Water admitted to the Paradox Control from the pressure supply line should have close valves 2 and 4 ; and the needle valve will be ready for use.
full reservoir head and should be strained through a screen not coarser than V TO WITHDRAW VALVE FROM SERVICE WHEN THE NEEDLE IS IN ANY
16 mesh . POSITION :
D. Proper functioning of the valve requires that the interior chambers A , A' and B A. Close valve I and open valves 2,3,4 , and 5.
in the valve be completely filled with water at all times . The purpose of the B. Rotate handwheel on Control Stand in a counterclockwise direction as far as
Gooseneck is to maintain the water within the valve at the proper elevation. it will go.
Handwheel C. When water stops running from drain line the interior chambers A , A, and B
E. Service valve strictly in accordance with the following instructions.
Pointer ITO PUT VALVE INTO SERVICE WHEN THE NEEDLE IS IN THE OPEN will be drained.
CONTROL STAND-- POSITION: VI GENERAL INSTRUCTIONS :
A. Rotate handwheel on Control Stand in a counterclockwise direction as far as it A. To open valve after servicing rotate the handwheel on the Control Stand in a
Brake screw-- will go. counterclockwise direction . To close valve rotate the handwheel in a clockwise
B. Close valves 3 and 5 , and open valve I about one - fourth , and fully open valves direction .
--AIR VENT MANIFOLD 2 and 4 B. To regulate the speed at which the Needle moves increase or decrease the
C. Wait until air vent cap on Air Vent Manifold from chamber B rises and water opening of valve I.
begins to flow from valve 4 , then close valves 2 and 4 and the needle valve C. Do not mistake the tendency of the Needle to slow down when it nears the fully
---Drain pipe will be ready for use. opened or fully closed position as a tendency to stick. This slowing down is
III TO PUT VALVE INTO SERVICE WHEN THE NEEDLE IS IN THE CLOSED intentionally accomplished due to a constricting of the valve ports.
POSITION: D. Any tendency of the needle to creep during operation may be corrected by
--Air vent from Chambers tightening the brake screw on the underside of the Control Stand.
A and A' A. Rotate handwheel on Control Stand in a clockwise direction as far as it will go.
B. Close valves 3 and 5 , and open valve I about one - fourth and fully open E. After the first year in service , the needle, diaphragm tube and body extension
--Air vent from Chamber B valves 2 and 4. should be removed and inspected for the accumulation of scale on the finished
C. Wait until air vent cap on Air Vent Manifold from chambers A and A' rises and bronze surfaces . Any scale which has formed shall be removed , and the amount
water begins to flow from valve 4 , then close valves 2 and 4 and the needle of scale present shall be noted and used as a guide in determining advisable
<--Air vent from water valve will be ready for use. future cleaning intervals .
passageway
-BODY Vent pipe----
Invert of Gooseneck Flow-

. in
PIPE LINE- PIPE LINE-

M4
WATER PASSAGEWAY.
BODY EXTENSION

Top of Chamber A'

A
-B-

X
Closing Ports
Closing port-- DIAPHRAGM
NEEDLE TUBE-
Open
Opening NEEDLE
port- GOOSENECK
NEEDLE (Closed)
Closed

WATER PASSAGEWAY-

Strained pressure water

from reservoir for
operating Needle- --Provide Valve for draining
-Water Passageway interior valve chambers. SECTION X - X - VALVE CLOSED
drain valve when needle valve is with-
drawn from service.
---Drain line
Service By- Pass PARADOX CONTROL DEPARTMENT OF THE INTERIOR
BUREAU OF RECLAMATION
DENVER OFFICE
Regulating valve- INTERIOR DIFFERENTIAL NEEDLE VALVE
FIELD SERVICING AND OPERATING

BHS
INSTRUCTIONS

.
LONGITUDINAL SECTIONAL ELEVATION OF NEEDLE VALVE DRAWN ...WH.K......SUBMITTED. Algang.

.11-23-30
AND SCHEMATIC ARRANGEMENT OF OPERATING EQUIPMENT TRACED E.W.C. RECOMMENDED ..JabeLamp

10-7-49
Asubalter

MOM
CHECKED.W.6.W. APPROVED..

REV
DENVER ,COLO. ,JAN. 21,1937. 40-D-2480

Figure 13. -Drawing 40- D- 2480 , field servicing and

operating instructions of interior differential needle
valve.

29
 LIST OF PARTS - ONE VALVE
PART MATERIAL NUMBER DRAWING
NUMBER DESCRIPTION REQUIRED NUMBER
I Body Semisteel 40-0-2159
2 Operating stem bushing Rolled bronze 40-D-2160
3 Needle stem bushing Rolled bronze
LIST OF DRAWINGS 4 Rolled bronze 6

4567 89123
Needle quide
Needle quide Rolled bronze 2 "
VALVE Needle body Cast manganese bronze 40-D-2161
ASSEMBLY- LIST OF PARTS.. .40-D-2157 Needle tip Semisteel "1
LAYOUT DIAGRAM.. 40-D-2158 Rolled bronze M
BODY.. 40-D- 2159 Needle stem
Cold rolled steel и
BODY SECTIONS - BUSHINGS - NEEDLE GUIDES. 40-D-2160 Operating stem "
NEEDLE -NEEDLE STEM - OPERATING STEM. 40-D-2161 10 Packing For water I Set
NEEDLE SEAT -RETAINER - BEVEL GEARS- STUDS....40-D- 2162 Gland Rolled bronze I "1
Seat retainer Cast steel I 40-D-2162
Nozzle seat Cast bronze I
CONTROL STAND 1 "
ASSEMBLY -BODY -GEARS - LIST OF PARTS......... 40-D- 2163 14 Bevel gear Cast manganese bronze
15 Bevel pinion Monel metal "1
16 Cast bronze "1
Body tip
17 Bevel gear nut Rolled bronze I
18 14x52 Stud with nut Boltsteel- class "C" 20 11
19 "x2 "Needle stud with slotted nut Bolt steel - class "A" 16 H
20 x3911"Seat retainer stud with nut Bolt steel - class "A" 28 "
21 2x18"Tap bolt Bolt steel -class "A" 7 "
22 x2 Pushoff bolt Bolt steel -class "A" 7 11
23 4x "Round head capscrew Rolled bronze 36 11
24 Rolled bronze 18 "1
25 30 Round head capscrew
4"x2"
Rolled bronze 8 No detail
x "Flat head capscrew
26 44"OD.x22"1.D.X32"thick gasket Soft copper No detail
27 Dia. gasket Solid rubber 62 Feet No detail

C Control stand -complete I Unit 40-D-2163

CONTROL--

25

(26) (22)
+
20
>

-12," 21

+ 14
4000000
outlet
inlet

Dia.
Dia.
-22"

18"
-28"
274

Dia.
Dia
Dia.-
B.C"

33".
L
<
>
29"

A
+

(12)
Travel-
肚

(27)
mechanically
assembly
Drawing
operated
Figure
2157,
needle
inch
valve.
14.
40
18
of
D
--

MECHANICALLY
CHECKED.774K.

2-10"-
SUBMITTED

OPERATED

Drain pipe-
8-26-59 DRAWINGS
TRACED
DRAWN.
ASSEMBLY
NEEDLE
J.E.V..

BH3D.MODIFICATIONS.
L.E.F
FL.M..-.

VALVE

Designed
pressure
working
square
PARTS

inch
DEPARTMENT

per
for
18"

120
lbs..
LIST

RECLAMATION
RECOMMENDED

20026
FRIANT
19680
VALVE
OF

AND
SEE
..APPROVED

214-
214D-
DAM
FOR
DENVER

BUREAU
OF
COLO.

DENVER
FEB.
19356,,

OFFICE

24
31

SHEET

OF

12
OF6I

INTERIOR
NalteA.

13
THE
I.
.t
..

PARTIAL SECTION A-A

2157
40
D-
 24
2-25
3-3-
drainholes

5-3
-2-4
4-0"

O
V -3
4-2½" 20% DEPARTMENT OF THE INTERIOR.
3-72"
UNITED STATES RECLAMATION SERVICE.

I
9'-98
NORTH PLATTE PROJECT-NEBR.& WYO.
MINATARE DAM
24"NEEDLE REGULATING VALVE
SCALE DRAWN H.E.S. RECOMMENDED:........ ambaylor
CHECKED:REB APPROVED ..
2 Denver, Colorado -February 1,1922 20-E- 229
HES
Figure 15.- Drawing 20- E - 229 , Minatare
Dam 24 -inch needle regulating valve .

33
 OPERATION AND MAINTENANCE PROBLEMS

General

This section identifies the problems most often reported in the operation and maintenance
of needle valves . The problems , underlying causes , and the characteristics of the valves are
discussed in detail . Corrective action is stated only in general terms . Recommended operating
practices and repair procedures are covered in detail in the following sections.

Operating personnel should be sensitive to changes in valve action . Any change from normal
is an indication that maintenance will soon be required . Continuing neglect can result in
complete failure of the valve to operate . A malfunction is usually not limited to one problem,
but is a combination of two or more . If a valve is disassembled to correct one problem , it
should be given a complete overhaul to correct all deficiencies .

A study of the operating chamber arrangement on all types of water- operated needle valves
reveals that the designers provided a larger force to close the valves than to open . What
was not a design consideration but did add an extra closing force is a subatmospheric
pressure created on the needle by the discharging water . As a result , difficulties with the
valves will often appear first during the opening cycle rather than the closing . The needle
on any of these valves is held in an intermediate position only by a balance of hydraulic
forces and the friction load on needle . The position is not positively held as it would be
on a mechanical valve , but is influenced by any condition that upsets the balance of hydraulic
forces.

Any problem with these valves will be more pronounced at low reservoir . The hydraulic forces
operating the needle decrease in proportion to the decrease in available head . If poor
operation at low reservoir is due only to the loss of head , a booster pump can be installed
in the supply line to increase the effective head . The boost pressure must be limited to the
design head of the valve . A booster pump should not be used at normal heads or in an effort
to overcome other problems and delay needed maintenance .

Drifting and Sluggish Operation

Water-operated needle valves respond to control handwheel movement only as fast as water
can flow in and out of the valve chambers , which is somewhat slower than the handwheel
can be turned . It is necessary , by experience , to learn the speed at which an individual valve
responds . Valve response may be slower at low reservoir. A valve can be termed sluggish
only if the response becomes somewhat slower than normal . Any change can be expected
to take place slowly over a number of years and may go unnoticed until the response has
deteriorated badly.

35
When changing the opening of a valve , it is not unusual that the handwheel must be jockeyed
for a few minutes before the valve holds the new opening . Drifting is that tendency of a
valve to move off the set position at some later time .

Both of these problems are normally due to wear on mating surfaces . These are the surfaces
where parts of the valve (such as bull rings and liners) meet in sliding contact and divide the
interior of the valve into operating chambers . Sliding surfaces of control units are also critical,
in particular the sleeve and piston on paradox controls . Wear allows excess water leakage
into , out of , or between valve chambers as the individual case may be . On the paradox
control , the leakage past the piston goes directly to drain and never enters the valve
chambers . The quantity of water available to operate the valve is decreased by the amount
of leakage . Or , in some cases , leakage into a chamber may result in too much water. It
naturally follows that needle movement is slowed and the operating forces in the valve
chambers are decreased . As the amount of leakage approaches the inflow rate of control
water, the situation becomes critical and control of the valve may be lost.

When either drifting or sluggish operation is identified as a definite problem , a complete

overhaul (figs . 16 and 17 ) should be scheduled as soon as practicable . These problems only
get worse and a delay could result in failure of the valve to operate under some adverse
or unexpected condition . For those valves with paradox controls, it may be that repair of
the control unit will correct the problem but, in most cases , an overhaul of the valve should
also be done . It is necessary that the clearances between mating parts be reestablished to
that given on the drawings . In most cases, it is not necessary to hold the exact drawing
dimensions for diameter of the parts, but it is important that the clearance between parts
be in accordance with the drawings .

Sticking

Sticking , as used here , is that condition in which a valve operates satisfactorily through partial
travel , then stops (sticks) in a partly open position and will not move further in that direction
of travel. This is caused by conditions that close up the clearances between moving parts.
Scale buildup on the bronze surfaces is the usual cause , but it can be any hard deposit .
Another condition is the apparent growth of valve parts due to the buildup of galvanic
corrosion products in the interface between mating bronze and cast iron ( or other ferrous
metal ) parts.

Scale is a hard mineral deposit formed on metallic surfaces in contact with water. The severity
of this problem is largely determined by the water quality; that is , " the harder the water,
the heavier the scale deposit . " Also , the buildup is heavier on bronze than on stainless steel.
Regular operation of a valve through full travel will scrape off much of the scale as it forms.
But once the valve sticks , it must be disassembled and the scale removed .

Galvanic corrosion will occur when bronze and cast iron , semisteel , or steel are in close
contact in the presence of water. This takes place slowly and normal inspection shows no

36
 Figure 16.-Removing needle-60- inch internal differential needle valve .

Figure 17. - Body extension after overhaul- 54-inch interior differential needle valve .

37
apparent damage to the metal parts . The black corrosion products are the problem . After
they have filled the clearance between parts , they continue to grow forcing the surfaces
apart. This puts the outer part in tension and the inner part in compression . The lighter part,
usually the bronze part , takes the greater deformation . The stretch or compression in these
parts can close off normal working clearances or even break the weaker part. To check for
this condition , the needle valve must be disassembled and all surfaces in sliding contact
thoroughly cleaned of scale and other foreign material . Then the diameter of these surfaces
must be accurately measured . If the measurements indicate a change from the drawing.
dimensions in some parts , these parts and mating parts must be disassembled as required
to remove the corrosion products . Removal of the products will restore original clearances .

Silt and Trash

Silt and trash deposited in water-supply lines and in interior water passages of needle valves
interfere with control waterflow slowing down the needle movement . Filters in supply lines.
must be regularly cleaned and maintained in good condition . A filter can be added if it was
not originally provided . Silt should be flushed from the supply line and the valve interior on
a regular basis.

Cavitation.

Loss of metal from the surface of needle valve parts can be caused by the action of the
flowing water. Two conditions often encountered are termed erosion and cavitation . Erosion
is normally identified by a rather even loss of surface metal over a given area or can be
a definite pathway cut on the mating surfaces of seats or other closely fitting parts . Cavitation
damage is characterized by a pitted , uneven appearance . Erosion is normally the lesser
problem and the repair of eroded surfaces is much the same as repair of cavitation damage .
On many needle valves , cavitation damage is a major problem .

The principles of cavitation were poorly understood when most of the needle valves were
designed . Laboratory studies made in about 1940 established design criteria to avoid
cavitation damage in needle valves . These criteria were used in the design of the Friant Dam
valves, but older valves are subject to cavitation problems.

Cavitation is produced by high velocity waterflow over a surface when the surface contour
is such that negative (subatmospheric) pressures occur . The resulting loss of metal from the
surface is referred to herein as cavitation damage . The laboratory tests established the
following three considerations to be necessary to maintain positive pressures in a needle
valve : ( 1 ) the angle between the needle and nozzle must not be diverging ; ( 2 ) the nozzle
should have a sharp- edged exit ; and (3) the seating point of the needle must be on the cone
portion . Since these considerations had not been established when all but the Friant Dam
valves were designed , a common pattern of cavitation damage can be found on nozzles ,
needle seats, and needle cones . The potential for cavitation is greater as the flow velocity
increases; so it follows that, other considerations being equal , the higher the operating head

38
the greater the damage will be . The appearance of cavitation damage is shown on figure.
18. This type damage should not be neglected as it always gets worse and one damaged
area will trigger another downstream . Repairs should be made before the damage is too
extensive and , as a general rule , before any of the pits are more than 1/4 inch deep . On
thin and sensitive parts, it should be sooner.

Repair of cavitation damage normally involves one or a combination of the following : ( 1 )

modification; (2) replacement of parts ; or (3) welding repair . Modification is a desirable
approach as the potential for cavitation can be reduced but it is normally the most expensive
and decreases the discharge capacity of the valve . Modification should follow the three
considerations stated above . The nozzle seat should be replaced with one giving both
convergence and a sharp exit . Sometimes the needle seat can be built up with weld metal
and refinished to improve the contour . Badly cavitated parts can be replaced , but often it
is more economical to repair by welding . Again , if the contour of replacement parts or weld
repaired parts can be improved , this should be done.

Parts Breakage

Parts breakage can occur from many reasons but is usually caused by some unusual condition
that produces shock or overload . Proper maintenance and good operating practices will
largely eliminate this problem . Care must be used in filling and venting the valve chambers ;
in particular, this is true of the older valves which are filled from the water passage .

Zinc bronzes are subject to dezincification in the presence of water . This can result in cracking
and breakage of parts , in particular , bolts , even when there is no overload or shock involved .
Zinc bronzes should not be used on these valves .

39
 4

Figure 18.-Cavitation damage on needle-80 - inch interior differential needle valve .

40
 RECOMMENDED OPERATING PRACTICES

General

Good operating practices and regular preventive maintenance can prevent or delay the need
for major repairs.

Remember that needle valves are operated by hydraulic forces . The handwheel controls only
the flow of control water and has no mechanical link to the needle . A handwheel should
never be forced as this can only result in a broken shear pin . Allow the needle to move at
its own speed and follow at the same pace with the handwheel . Never replace the shear
pin with one of higher strength material as it is there to protect other parts of the control
from overload .

On interior and internal differential needle valves with paradox controls , proper adjustment
of the brake on the control stand will help to prevent valve drifting when other operating
conditions are met . Adjustments should be made in small increments.

Exercising Valves

Regular exercising of any type equipment is required to keep moving parts free and operating
properly. This is especially true of needle valves . All the moving parts are in contact with
water and subject to scale and other deposits which are very detrimental to good operation .
Frequent exercising will remove most of these deposits and otherwise keep the needle
movement free . It is important to operate through full travel . All needle valves should be
exercised twice a year by operating from closed to fully open and back to closed .

Flushing Valve Interiors

The interior needle valve chambers and control water passages should normally be flushed
once a year to remove silt and other foreign material . However, the need varies according
to the silt load in the water, and at installations with a light load , flushing can be less frequent .
Where the silt load is heavy, flushing may be required twice a year . The water-supply line
should be flushed at the same time .

It is best to do the flushing as soon as practicable after taking a valve out of service to give
the silty mud less time to dry and cake . Use a pressure base to reach all possible interior
passages and chambers . As appropriate for each valve , remove the control unit and any
manhole covers . Work through these and any other available openings into the valve . Flushing
should also be done through vent , drain , and pressure connections into areas that cannot
otherwise be reached .

41
Flush the supply line with reservoir water . If an opening is not available to release the flush
water, a tee should be installed . Usually this can be done by replacing an elbow just ahead
of the control unit.

Filling Valve Chambers

Care must always be used when filling the needle valve chambers . If these chambers fill
unequally and water pressure starts to build up in only one chamber, an unbalanced force
will be placed on the needle . This force can produce unexpected movement of the needle
and a shock on internal parts which may cause damage or breakage . Always fill slowly so
that chambers can fill as evenly as possible . Keep air vents open until all chambers are filled
to prevent unequal pressure buildup .

The interior and internal differential needle valves present no unusual filling problem as long
as the instructions are carefully followed . Never open filling valves more than specified in
the operating instructions . They can be opened a lesser amount for slower filling . Be sure
the air vents are open and working properly.

The balanced needle valves present a special filling problem as they do not have separate
filling lines but are filled directly from the water passage . This requires that the valves be
in the closed position when drained and filled . It also means that a large space must be
filled (the pipeline downstream from the guard gate and the water passage of the valve) so
that the temptation to fill too fast is great . Compounding this problem is the situation that
the opening chamber fills much faster than the closing chamber . This all adds up to " FILL
SLOWLY" and keep air vents open . Just cracking the filling valve open and allowing overnight
for filling is recommended .

Unusual Conditions

In the event of some unusual occurrence , such as an abnormal noise from the valve which
might indicate a broken part or for any reason control of the valve is lost, the control
handwheel should be turned as far as possible in the closing direction (clockwise ) . This can
prevent further damage to the valve and uncontrolled flow from the outlet.

When sluggish operation of a needle valve occurs due to low reservoir head , the valve
operation can sometimes be helped by opening the proper drain valve . For needle valves
with paradox controls , this is the drain valve bypassing the gooseneck . For other needle
valves , it is necessary to study the drawings and the diagrams on the operating instructions
to determine which drain valve will aid the desired needle movement . The drain valve should
be opened only when the needle valve opening is being changed and should be closed as
soon as the new setting is reached .

At the end of the irrigation season , the reservoir water pressure at some dams is insufficient
to close balanced needle valves . The following procedure was developed as an employee

42
suggestion for use at McKay Dam and could be used on other valves having a sleeve -type
control unit . (Previously the needle was closed by removing the control unit , entering the valve
chamber and forcing the needle closed with jacks .) A separate pressure water supply must
be brought to the valve by a pressure hose . If reservoir water is used , valve closure will need
to wait for a rise in reservoir level unless a small booster pump is installed in the water- supply
line . Boost pressure must be limited to the design pressure of the valve . Proceed as follows :

1. Remove the control cylinder cover and related parts .

2. Remove the inner control sleeve and control shaft .

3. Turn the outer control sleeve so that the opening matches the drain and close the
drain valve .

4. Provide and install a specially made plate in place of the control cylinder cover. This
plate must be provided with a tap for attaching the water- supply hose.

5. Open the pitot valve halfway.

6. Attach the water-supply hose and fill and vent the needle valve chamber.

7. When the chamber is full , slowly close the pitot valve until the needle moves .

8. With the needle valve closed , shut off water supply , drain the valve , and restore to
normal condition .

43
 REPAIR PROCEDURES

Cleaning and Descaling

The first action to be taken after disassembly of a needle valve or control unit for inspection
or repair is thorough cleaning and descaling . All silt and other foreign material should be
cleaned from the interior surfaces with particular attention being given to ports and water
passages between chambers . All scale on contact surfaces must be removed to bright metal .

Scale is difficult to remove and certain safety precautions must be taken . Acid descaling has
been tried but it leaves a hard residue which still must be removed by mechanical means .
Sanding with wet or dry paper of 200-300 grit is a recommended procedure . Care must be
used not to oversand and remove metal but to stop as soon as bright metal appears . Dust
from this procedure is highly toxic and must not be breathed . In addition to the use of normal
safety equipment and procedures, the working surfaces must be kept wet . The residue will
then be a thin mud rather than dust and can be more safely disposed . Contact of the residue.
with the skin must be prevented .

Surfaces in Sliding Contact

After the sliding contact surfaces on the interior of the needle valves have been cleaned
and descaled , the diameter of mating parts should be carefully measured and the clearance
between parts calculated . Because larger parts may distort due to their own weight , they
should be positioned to minimize this problem . Make several crisscross measurements to
determine the average diameter and the amount of out-of- roundness . Use dial indicators
mounted on a swinging axis to check for distortion in large cylinders . The actual dimensions
of parts are not as important as the clearance between mating parts . The clearance should
be in the range specified on the drawings ; it should not be greater or less .

When the clearance is less than the drawing range , a buildup of galvanic corrosion products
in the interface between the bronze parts and mating ferrous parts is indicated . These
corrosion products will cause expansion of bull rings and similar parts and shrinkage of sleeves
and liners. This distortion will be relieved when the corrosion products are removed . The
bronze parts must be disassembled from the mating ferrous parts . It can be expected that
the fit will be very tight and force will be required . All corrosion products must be removed
from the mating surfaces . Reassemble the parts coating the mating surfaces with a product.
designed to minimize seizing and to exclude water , such as Armite Labs No. 25 , Led - Plate ,
or other similar product . By excluding water from the interface , future galvanic corrosion can
be prevented .

When the clearance is greater than that specified on the drawings , one of the parts must
be replaced or repaired as described under " Repairing or Replacing Parts , " page 33 , and
turned to restore proper clearance . If the mating part is enough out-of - round to prevent
restoring of the proper clearance , it must first be bored or turned as lightly as possible to

45
restore roundness . The use of field boring bars may be necessary where valve bodies are
encased in the concrete valve house walls .

Another problem often discovered on valve disassembly is stuck piston rings . These will stick
in a compressed position but when freed will expand back to normal . The ring and groove
must be cleaned and the groove width increased to provide more freedom of ring movement .
This can be done by turning about 0.010 - inch from the side of the groove or by shimming
the ring retainer an equal amount .

Paradox Controls

Problems with paradox control units ( figure 8, drawing 40 - D - 1090) are normally caused by
wear on the mating , sliding surfaces of the control liner and the control piston . Good
appearance of these units can be misleading . Measurements of the lands on the piston and
the inside diameter of the liner must be carefully made and the clearance calculated . Make
measurements at three equally spaced diameters on each land and at enough places on the
inside of the liner to detect worn areas . Normally the heaviest wear will occur on the center
land of the piston and good fit on this land is critical to good performance .

When the measurements show wear on these parts , the clearance between the liner and
piston must be restored to that specified on the original drawings . The clearance can be
less as long as there is no binding , but it should not be greater . It is not necessary to hold
the exact drawing dimension for the diameter of these parts so long as the correct clearance
is restored for the full contact length of the parts.

Both the liner and piston can be replaced with new parts but this is not usually necessary.
Normally the most economical repair procedure is : true the inside surface of the liner by
machining, build up the piston lands with weld metal , and refinish the piston lands . When
refinishing, care must be used to retain concentricity of the parts . The liner should not be
removed from the control body for machining and the amount of metal removed should be
held to a minimum . Use care to prevent distortion of the piston , particularly when applying
weld metal . Mount the piston on a special steel mandrel for welding and machining. Another
repair procedure which has been used is to remachine the piston removing just enough metal
to true the lands and replace the liner with one bored to match the slightly reduced diameter
of the piston .

Cavitation Damage

Figure 19 (drawing 32 - D - 618) , shows modifications to the nozzle seat of a 60- inch balanced
needle valve . The modification involves replacement of the damaged ( by cavitation) nozzle
seat with one having a modified contour and reboring of the seat retainer to match the
downstream diameter of the modified seat . The replacement seat is provided with a water
passage contour that meets the three considerations established by laboratory tests and set
forth on page 38. It has an angle between the needle and nozzle that is converging ; it

46
 NOTE
Nozzle seat may be cast from aluminum bronze,
Fed. Spec. QQ - B - 671b, Class 1 or fabricated
from stainless steel, Fed. Spec. QQ - S- 766 C,
Class 304L. The nozzle seat may also be
Remove any offsets between fabricated from the following alternate materials:
body and seat by grinding aluminum bronze bars - ASTM B150, continuous
and fair smoothly into cast aluminum bronze bars -QQ -B-671b, stainless
adjacent surface. steel bars - QQ - S- 766C, Classes 304, 316L, 321
347. If ring is fabricated from bronze bars,
it shall be annealed after welding.

See note 9
3.741

If valve leakage is excessive when

closed, smooth needle surface so
that all roughness or ridges are

16

.65.500
removed, then blue and scrape

2
nozzle seat as necessary to produce

Dia
Original an acceptably tight seal. A contact
4.146 Surface

"
surface of to should produce
a tight seal.
Re-machined
surface

920
Leave sharp

Dia
edge.

.61
UNITED STATES
DEPARTMENT OF THE INTERIOR

"
BUREAU OF RECLAMATION
YAKIMA PROJECT - WASHINGTON
STORAGE DIVISION
TIETON DAM
60" BALANCED NEEDLE VALVES
MODIFICATIONS TO NOZZLE SEATS
SECTION THRU VALVE SEAT
DRAWN.... 195.0 SUBMITTED. 2. O
TRACED... RECOMMENDED W
CHECKED Shel
APPROVED HEMECHANICALHARCH
DENVER, COLORADO APRIL 14, 1965 32-0-618
SHEET I OF

Figure 19.-Drawing 32- D- 618, modifications

to nozzle seats- 60-inch balanced needle
valves.

47
provides a sharp- edged exit ; and it seats on the cone portion of the needle . It also provides
free access of air to the jet as it leaves the nozzle . This modification should eliminate
.
cavitation damage on the nozzle seat , either eliminate or substantially reduce the damage
on the needle seat, and reduce the damage on the needle cone . It does , however, reduce
the needle travel resulting in a reduction in the maximum discharge capacity of the needle
valve . Unless it is essential to retain the maximum capacity of the valve , this modification
should be followed as closely as possible whenever repairs for cavitation damage are made .
It is possible that some old seats can be built up with weld metal and remachined to the
modified contour rather than being replaced .

Repair of cavitation damage on the needle and similar areas is normally accomplished by
building up the surface with weld metal and then grinding back to contour . On some valves ,
the needle seat can and should be replaced with one of stainless steel or aluminum bronze
for added cavitation damage resistance . Before placing weld metal , the damaged surface
should be ground or chipped to sound , bright metal . The area to be welded should not be
ground to a feather edge , but should have an abrupt shoulder . The welding rod used to build
up the overlay must be compatible with the base metal . Aluminum bronze and stainless steel
are highly resistant to cavitation damage and should be used when possible . The new metal
must be ground to a smooth , even contour . A template (fig . 20) should be used to maintain
the proper contour . Any ridges , bumps , or indentations left on the surface will trigger new
cavitation .

Figure 20.-Checking needle with template-60-inch internal differential

needle valve .

49
Welding

Welding can be used to good advantage in the repair of needle valves and the fabrication.
of replacement parts . This bulletin does not attempt to give detailed welding information .
Power Operation and Maintenance Bulletin No. 24 is an excellent source of general
information on welding and , in particular, on the welding repair of cavitation damaged parts .

Care and good welding techniques must always be used to avoid distortion of parts during
welding . Fixtures and precautions similar to that described in Power O&M Bulletin No. 24
should be used for needle cones and similar parts where distortion due to welding can occur.

Welding of cast iron should not be done when full strength is required from the part as the
parent metal is weakened in the heat affected zone . Weld is normally satisfactory for
overlaying cavitated areas and for nonstrength parts .

Welding techniques and capabilities are constantly undergoing improvement . It is well to

seek the latest information from the major suppliers of welding rod and equipment concerning
the proper rod , technique , etc. , to use for any given application .

Repairing or Replacing Parts

Having identified valve parts that are worn or for other reasons are no longer in serviceable
condition, one is faced with several choices of repair procedures and materials . Cost is
always a major factor but it is more important that the repair be fully effective . Many of
the factors involved are discussed here so that a good choice can be made .

Most of the parts on these valves are castings which were a good economical choice at
that time . Now casting is normally an expensive choice , particularly when only one part is
required . For some parts, a replacement casting may be the most effective repair and should
be chosen , but in most cases , economics will rule otherwise . Consideration should always
be given to fabrication of new parts by welding . Replacements for cast iron and semisteel
parts should, whenever possible, be fabricated from steel as this is not only cost effective ,
but gives a higher strength part that is easily repaired by welding .

Materials selection is a major consideration . It is not necessary and sometimes not desirable
to make a replacement part of the same material as the original . Steel is normally to be
preferred over cast iron or semisteel , whether the part is to be cast or fabricated by welding .
Steel is more subject to corrosion damage but this is not a serious problem . It is more than
offset by the advantages of ductility , higher strength , and ease of weld repairs . In repairing
or replacing bronze parts that are in sliding contact , the preferred materials are aluminum
bronze sliding on stainless steel . These not only have good properties in sliding contact but
both are highly resistant to cavitation damage and easily repaired by welding . Normally only
one of the surfaces will need replacing . In this case , stainless steel is preferred but aluminum
bronze is entirely satisfactory . The one combination that should be avoided is stainless steel

50
sliding on stainless steel as this combination is subject to galling and seizure . The normally
used alloys of aluminum bronze and stainless steel are not as strong as the cast manganese
bronze used in many of the original parts . In most cases , they are still satisfactory substitutes ,
but if full strength is required , a higher strength bronze should be used . Aluminum bronze
parts can be cast or fabricated by welding . Stainless steel parts can be cast but normally
.
should be fabricated . Type 304L stainless steel is preferred but types 304 , 316L , 321 , and
347 are fully satisfactory . One further precaution : do not use zinc bronzes for replacement
parts because of the problem of dezincification in contact with water.

In many cases , repair of worn or damaged parts is satisfactory as well as more economical
than replacement . Where worn or damaged surfaces must be built up , a weld overlay
machined to provide the proper dimension and surface texture is often the best choice . The
original surface must be cleaned or machined to sound , bright metal before welding . The
overlay should be thick enough so that the final machined surface will be in the weld metal
and not in the interface between the weld and parent metals . Normally obtaining this
thickness will require machining or grinding metal from the original surface before applying
weld metal . The welding rod must be compatible with the parent metal . Stainless steel or
aluminum bronze rods are preferred if compatible . Figure 21 (drawing 33 - D- 3965) shows a
procedure used to apply a stainless steel band ( ring ) on the periphery of a bull ring . This
is an effective alternate to a weld overlay and can be used on any similar part . The band
could also be fabricated from aluminum bronze . Often it is economical to replace an entire
cast ring with a fabrication as shown for the nozzle seat on figure 19 on page 47. This method
can be used for any ring of relatively simple cross section made of any weldable material .

**

51
 125/Finish on bull ring.
Allow approx.
x.1 for finish. MODIFICATION PROCEDURE
6"

125
10100
Normal 1.Machine a groove in the bull ring, part 21, as
shown.
63/
Calk edge of bronze 2.Provide stainless steel plates, bent into a ring
Chamfer bull ring tight against and machined as shown to fit in the groove of
stainless steel ring on the bull ring. The edges and chamfer should

suit
er er
both sides . be machined on the plates before bending . Only

O.D.
1.D.
of
To
the edges of the plates require machining.

linind
3.Clamp the stainless steel ring sections tight
16 Chamfer

cyl
5Finish stainless around the rim of the bull ring . The ring may

81
plates to .010 " to

. ia
be clamped down tight by using a series

Dia3
-7
015"less than groove,

78
of C- clamps ( at least 15 on each side) around

D
"

."
width in bull ring.
the rim, or by using two wire ropes tight-
ened down with furnbuckles, or other
means, around the rim of the bull ring.
4. Weld both joints of the stainless steel ring
simultaneously so that the ring will shrink
to a tight fit around the hub when it cools.
5.Calk the edges of the bull ring tight against
the stainless steel ring.
SECTION A- A 6.Machine the stainless steel ring for proper
clearance in the rebored piston cylinder
7. The three 14 inch radius grooves can be
eliminated on the stainless steel ring.

As rolled

16
B

a
i
D
4 Stainless steel
8
7

UNITED STATES
DEPARTMENT OF THE INTERIOR
BUREAU OF RECLAMATION
DETAIL B YAKIMA PROJECT- WASHINGTON
TIETON DAM
60- INCH BALANCED NEEDLE VALVE
RING DETAIL DRAWNJ.SO. SUBMITTED4
STAINLESS STEEL 18-8 TRACED.-- --RECOMMENDED
CHECKED APPROVED NE
EWTYMECHA .Skeda
NIC AND-
DENVER, COLORADO
SHEET LOE L 11-17-64 33-D-3965

Figure 21. - Drawing 33 - D - 3965 , bull

ring-60-inch balanced needle valve .

53 GPO 832 - 174