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ANSI/AWWA C515-09 (Revision of ANSI/AWWA C515-01)

The Authoritative Resource on Safe Water®

AWWA Standard

Reduced-Wall, ResilientSeated Gate Valves for Water Supply Service SM

Effective date: Nov. 1, 2009. First edition approved by AWWA Board of Directors Jan. 24, 1999. This edition approved Jan. 25, 2009. Approved by American National Standards Institute Sept. 11, 2009.

6666 West Quincy Avenue Advocacy Denver, CO 80235-3098 Communications T 800.926.7337 Conferences www.awwa.org Education and Training Science and Technology Sections Copyright © 2009 American Water Works Association. All Rights Reserved.

AWWA Standard This document is an American Water Works Association (AWWA) standard. It is not a specification. AWWA standards describe minimum requirements and do not contain all of the engineering and administrative information normally contained in specifications. The AWWA standards usually contain options that must be evaluated by the user of the standard. Until each optional feature is specified by the user, the product or service is not fully defined. AWWA publication of a standard does not constitute endorsement of any product or product type, nor does AWWA test, certify, or approve any product. The use of AWWA standards is entirely voluntary. This standard does not supersede or take precedence over or displace any applicable law, regulation, or codes of any governmental authority. AWWA standards are intended to represent a consensus of the water supply industry that the product described will provide satisfactory service. When AWWA revises or withdraws this standard, an official notice of action will be placed on the first page of the classified advertising section of Journal AWWA. The action becomes effective on the first day of the month following the month of Journal AWWA publication of the official notice.

American National Standard An American National Standard implies a consensus of those substantially concerned with its scope and provisions. An American National Standard is intended as a guide to aid the manufacturer, the consumer, and the general public. The existence of an American National Standard does not in any respect preclude anyone, whether that person has approved the standard or not, from manufacturing, marketing, purchasing, or using products, processes, or procedures not conforming to the standard. American National Standards are subject to periodic review, and users are cautioned to obtain the latest editions. Producers of goods made in conformity with an American National Standard are encouraged to state on their own responsibility in advertising and promotional materials or on tags or labels that the goods are produced in conformity with particular American National Standards. Caution Notice: The American National Standards Institute (ANSI) approval date on the front cover of this standard indicates completion of the ANSI approval process. This American National Standard may be revised or withdrawn at any time. ANSI procedures require that action be taken to reaffirm, revise, or withdraw this standard no later than five years from the date of publication. Purchasers of American National Standards may receive current information on all standards by calling or writing the American National Standards Institute, 25 West 43rd Street, Fourth Floor, New York, NY 10036; (212) 642-4900.

All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording, or any information or retrieval system, except in the form of brief excerpts or quotations for review purposes, without the written permission of the publisher.

Copyright © 2009 by American Water Works Association Printed in USA

ii Copyright © 2009 American Water Works Association. All Rights Reserved.

Committee Personnel The AWWA Standards Committee on Taste and Odor Control Chemicals, which reviewed and approved this standard, had the following personnel at the time of approval: Roland L. Larkin, Chair S.K. Batra, City of Detroit, Water & Sewerage Department, Detroit, Mich.

(AWWA)

J. Bottenfield, Clow Valve Company, Oskaloosa, Iowa

(AWWA)

M.H. Burns, One Bolt Inc., Denver, Colo.

(AWWA)

L.R. Dunn, U.S. Pipe & Foundry Company, Birmingham, Ala.

(AWWA)

L.W. Fleury Jr., Mueller Group, Smithfield, R.I.

(AWWA)

S. Flora, M&H Valve Company, Anniston, Ala.

(AWWA)

J.J. Gemin, Earth Tech (Canada) Inc., Kitchener, Ont.

(AWWA)

T.R. Ingalls, East Jordan Iron Works Inc., East Jordan, Mich.

(AWWA)

R.L. Larkin, American Flow Control, Birmingham, Ala.

(AWWA)

R. Looney, American AVK Company, Minden, Nev.

(AWWA)

T.J. Mettler, Waterous Company, South St. Paul, Minn.

(AWWA)

K.J. Wright, East Jordan Iron Works, East Jordan, Mich.

(AWWA)

The AWWA Standards Committee on Gate Valves and Swing Check Valves, which reviewed and approved this standard, had the following personnel at the time of approval: Robert L. Gardner, Co-Chair Joseph J. Gemin, Co-Chair Thomas M. Bowen, Vice-Chair Roland L. Larkin, Secretary General Interest Members J.M. Assouline,* CH2M HILL, Englewood, Colo.

(AWWA)

R.L. Claudy Jr., Orlando, Fla.

(AWWA)

K.G. Clegg, CH2M HILL, Corvallis, Ore.

(AWWA)

D. Dieffenbach, Malcolm Pirnie Inc., Phoenix, Ariz.

(AWWA)

J.J. Gemin, Earth Tech (Canada) Inc., Kitchener, Ont.

(AWWA)

M.C. Johnson, Utah State University, Logan, Utah

(AWWA)

G.E. Laverick, Underwriters Laboratories, Northbrook, Ill.

(AWWA)



* Alternate iii Copyright © 2009 American Water Works Association. All Rights Reserved.

T.J. McCandless,* Standards Engineer Liaison, AWWA, Denver, Colo.

(AWWA)

P.I. McGrath Jr., Birmingham, Ala.

(AWWA)

T.R. Volz, URS Corporation, Denver, Colo.

(AWWA)

Producer Members J.V. Ballun, Val-Matic Valve & Manufacturing Corporaton, Elmhurst, Ill. J. Bottenfield, Clow Valve Company, Oskaloosa, Iowa

(AWWA) (MSS)

L.W. Fleury Jr., Mueller Group, Smithfield, R.I.

(AWWA)

S. Flora,† M & H Valve Company, Anniston, Ala.

(AWWA)

T.R. Ingalls,† East Jordan Iron Works Inc., East Jordan, Mich.

(AWWA)

R.L. Larkin, American Flow Control, Birmingham, Ala.

(AWWA)

R. Looney, American AVK Company, Minden, Nev.

(AWWA)

T.J. Mettler,† Waterous Company, South St. Paul, Minn.

(AWWA)

J.H. Wilber,† American AVK, Littleton, Colo.

(AWWA)

K.J. Wright, East Jordan Iron Works, East Jordan, Mich.

(AWWA)

User Members A. Ali, Metro Vancouver, Vancouver, B.C.

(AWWA)

T.M. Bowen, Manchester Water Works, Manchester, N.H.

(AWWA)

R.L. Gardner, Standards Council Liaison, Wannacomet Water Company, Nantucket, Mass.

(AWWA)

K.W. Gruber, East Bay Municipal Utility District, Oakland, Calif.

(AWWA)

K.S. Jeng-Bulloch, City of Houston, Houston, Texas

(AWWA)

J.S. Olson, Denver Water, Denver, Colo.

(AWWA)



* Liaison, nonvoting † Alternate iv Copyright © 2009 American Water Works Association. All Rights Reserved.

Contents All AWWA standards follow the general format indicated subsequently. Some variations from this format may be found in a particular standard. SEC.

PAGE

SEC.

PAGE

Foreword

5

Verification

I

Introduction...................................  vii

5.1

Testing...........................................  19

I.A

Background....................................  vii

5.2

Plant Inspection and Rejection.......  20

I.B

History...........................................  vii

6

Delivery

I.C

Acceptance.....................................  vii

6.1

Marking.........................................  21

II

Special Issues...................................  ix

6.2

Preparation for Shipment...............  21

III

Use of This Standard.......................  ix

6.3

Affidavit of Compliance.................  21

III.A Purchaser Options and Alternatives...  ix III.B Modification to Standard.................  x IV

Major Revisions...............................  x

V

Comments.......................................  x

Appendix A

Installation, Operation, and Maintenance of Reduced-Wall, Resilient-Seated Gate Valves

Standard

A.1

General..........................................  23

1

General

A.2

Unloading......................................  23

1.1

Scope...............................................  1

A.3

Receiving Inspection......................  23

1.2

Purpose............................................  2

A.4

Storage...........................................  24

1.3

Application......................................  2

A.5

Installation.....................................  24

2

References.......................................  2

A.6

Maintenance..................................  27

3

Definitions..................................... 

A.7

Repairs...........................................  28

4

Requirements

Tables

4.1

Data to Be Supplied by the

1

Design Torque . ...............................  9

2

Minimum Thickness of Body and

5

Manufacturer................................  6

Bonnet........................................  11

4.2

Materials..........................................  6

4.3

General Design................................  9

3

Excess Flange Thickness.................  11

4.4

Detailed Design.............................  10

4

Minimum Thickness for Ductile-Iron

4.5

Fabrication.....................................  18

Connecting End Flanges.............  11

v Copyright © 2009 American Water Works Association. All Rights Reserved.

SEC.

5

PAGE

Stem, Gate, Thrust Collar, and Stem Nut Copper Alloys......................  13

6

Stainless-Steel Valve Stem Alloys.....  14

7

Minimum Diameter of Stem and

SEC.

PAGE

8

Diameter of Handwheels................  17

9

Gear Ratios....................................  19

10

Proof of Design Torque..................  20

Minimum Number of Turns to Open...........................................  15

vi Copyright © 2009 American Water Works Association. All Rights Reserved.

Foreword This foreword is for information only and is not a part of ANSI*/AWWA C515.

I. Introduction. I.A. Background.  This standard describes reduced-wall, resilient‑seated gate valves with nonrising stems (NRS) and outside screw‑and‑yoke (OS&Y) rising stems, including tapping gate valves, for water supply service. The standard applies to water supply service having a pH range of 6.5 to 8.5 and a temperature range from 33° to 125°F (0.6° to 52°C). I.B. History.  The first edition of ANSI/AWWA C509 Standard for ResilientSeated Gate Valves was published in 1980. ANSI/AWWA C509 includes body and bonnet parts of either gray or ductile cast iron with shell-wall thicknesses equal to those of the ANSI/AWWA C500, Standard for Metal-Seated Gate Valves, which was first issued in 1952 as ANSI/AWWA C500 but had its roots going back to the first AWWA standard for gate valves, adopted June 24, 1913. In 1993, the AWWA Standards Committee on Gate Valves and Swing Check Valves received authorization from the AWWA Standards Council to prepare a standard covering reduced-wall, resilient-seated gate valves. Just as other recent AWWA standards have been developed as a result of the attendant strength of ductile iron (for pressure pipe and compact fittings), this standard results from its application for gate valves. The Manufacturer’s Standardization Society of the Valves and Fittings Industry (MSS) has played an important role in developing this standard. Founded in 1924, MSS has had official organizational representation on AWWA standards committees dealing with valve and hydrant products since 1930. This edition of ANSI/AWWA C515 was approved by the AWWA Board of Directors on Jan. 25, 2009. I.C. Acceptance.  In May 1985, the United States Environmental Protection Agency (USEPA) entered into a cooperative agreement with a consortium led by NSF International (NSF) to develop voluntary third-party consensus standards and a certification program for direct and indirect drinking water additives. Other members of the original consortium included the American Water Works Association Research



* American National Standards Institute, 25 West 43rd Street, Fourth Floor, New York, NY 10036.

vii Copyright © 2009 American Water Works Association. All Rights Reserved.

Foundation (AwwaRF) and the Conference of State Health and Environmental Managers (COSHEM). The American Water Works Association (AWWA) and the Association of State Drinking Water Administrators (ASDWA) joined later. In the United States, authority to regulate products for use in, or in contact with, drinking water rests with individual states.* Local agencies may choose to impose requirements more stringent than those required by the state. To evaluate the health effects of products and drinking water additives from such products, state and local agencies may use various references, including 1.  An advisory program formerly administered by USEPA, Office of Drinking Water, discontinued on Apr. 7, 1990. 2.  Specific policies of the state or local agency. 3.  Two standards developed under the direction of NSF†, NSF/ANSI  60, Drinking Water Treatment Chemicals—Health Effects, and NSF/ANSI 61, Drinking Water System Components—Health Effects. 4.  Other references, including AWWA standards, Food Chemicals Codex, Water Chemicals Codex,‡ and other standards considered appropriate by the state or local agency. Various certification organizations may be involved in certifying products in accordance with NSF/ANSI 61. Individual states or local agencies have authority to accept or accredit certification organizations within their jurisdiction. Accreditation of certification organizations may vary from jurisdiction to jurisdiction. Annex A, “Toxicology Review and Evaluation Procedures,” to NSF/ANSI 61 does not stipulate a maximum allowable level (MAL) of a contaminant for substances not regulated by a USEPA final maximum contaminant level (MCL). The MALs of an unspecified list of “unregulated contaminants” are based on toxicity testing guidelines (noncarcinogens) and risk characterization methodology (carcinogens). Use of Annex A procedures may not always be identical, depending on the certifier. ANSI/AWWA C515 does not address additives requirements. Users of this standard should consult the appropriate state or local agency having jurisdiction in order to 1.  Determine additives requirements, including applicable standards. 2.  Determine the status of certifications by parties offering to certify products for contact with, or treatment of, drinking water.

* Persons outside the United States should contact the appropriate authority having jurisdiction. † NSF International, 789 N. Dixboro Road, Ann Arbor, MI 48105. ‡ Both publications available from National Academy of Sciences, 500 Fifth Street NW, Washington, DC 20001. viii Copyright © 2009 American Water Works Association. All Rights Reserved.

3.  Determine current information on product certification. II. Special Issues.  This standard has no applicable information for this section. III. Use of This Standard.  It is the responsibility of the user of an AWWA standard to determine that the products described in that standard are suitable for use in the particular application being considered. III.A. Purchaser Options and Alternatives.  The following items should be provided by the purchaser: 1.  Standard used—that is, ANSI/AWWA C515, Reduced-Wall, Resilient-Seated Gate Valves for Water Supply Service, of latest revision. 2.  Whether compliance with NSF/ANSI 61, Drinking Water System Components—Health Effects, is required. 3.  Whether or not the purchaser requires cast ferrous valve components to be made of ductile iron. 4.  Quantity required. 5.  Special packaging for shipment as may be required for protection of coatings. 6.  Size and type of valve, NRS or OS&Y (Sec. 1.1). 7.  Whether or not the valve will be used in a corrosive environment (Sec. 1.1.3) determined by methods described in AWWA M27. 8.  Catalog data, net weight, and assembly drawings to be provided by the manufacturer (Sec. 4.1), if required. 9.  Details of other federal, state or provincial, and local requirements (Sec. 4.2). 10.  Whether or not the valve will be subjected to water that reacts chemically with materials used in these valves. Consultation with the manufacturer is advised to determine the suitability in cases of doubt (Sec. 4.2.3.3.3). 11.  Cutter diameter must be specified for tapping valves (Sec. 4.3.2). Note: Tapping machine shell cutters are made in either full size (outside diameter [OD] is full nominal size) or undersize (OD is less than full nominal size, i.e., usually ½ in. (13 mm) less [MSS* SP-113]). The purchaser should specify the size of the shell cutter the valve must accept. 12.  Type of valve ends—flanged (Sec. 4.4.1.4.1), tapping valve flange



* Manufacturers Standardization Society of the Valve and Fittings Industry, 127 Park Street NE, Vienna, VA 22180. ix Copyright © 2009 American Water Works Association. All Rights Reserved.

(Sec. 4.4.1.4.4), mechanical joint (Sec. 4.4.1.4.2), or push‑on joint (Sec. 4.4.1.4.3). 13.  Whether or not bolting material with physical and chemical properties other than ASTM* A307 is required (Sec. 4.4.4). It is recommended that the purchaser verify with the supplier the appropriateness of any alternative bolting materials required. What alternative, if any, is desired in the type of rustproofing for bolts and nuts (Sec. 4.4.4). 14.  Whether the valve is handwheel or wrench-nut operated and the direction in which the handwheel or wrench nut shall turn to open (Sec. 4.4.7). 15.  Detailed description of wrench nut, if not in accordance with Sec. 4.4.7. 16.  Whether or not records of tests specified in Section 5 are to be provided. 17.  Special markings (Sec. 6.1), if required. 18.  Affidavit of compliance (Sec. 6.3), if required. III.B. Modification to Standard.  Any modification to the provisions, definitions, or terminology in the standard must be provided by the purchaser. IV. Major Revisions.  Major revisions made to the standard in this edition include the following: 1.  Revised to cover 42-in. NPS and 48-in. NPS sizes. 2.  Revised to include integral and nonintegral thrust collar stem designs. 3.  Revised to include reduced flange thickness for flanged-end valves. 4.  Revised to include socket head and metric fasteners. 5.  Added additional copper alloys to Table 5. 6.  Revised to include the use of stainless-steel components (Sec. 4.2.3.5). V. Comments.  If you have any comments or questions about this standard, please call the AWWA Volunteer and Technical Support Group at 303.794.7711, FAX at 303.795.7603, write to the group at 6666 West Quincy Avenue, Denver, CO 802353098, or e-mail the group at [email protected].



* ASTM International, 100 Barr Harbor Drive, West Conshohocken, PA 19428. x Copyright © 2009 American Water Works Association. All Rights Reserved.

ANSI/AWWA C515-09 (Revision of ANSI/AWWA C515-01)

AWWA Standard

Reduced-Wall, Resilient-Seated Gate Valves for Water Supply Service Section  1: GENERAL Sec. 1.1

Scope This standard describes reduced-wall, resilient‑seated gate valves with nonrising stems (NRS) and outside screw‑and‑yoke (OS&Y) rising stems, including tapping gate valves, for water supply service having a temperature range of 33° to 125°F (0.6° to 52°C). These valves are intended for applications where fluid velocity does not exceed 16 ft/sec (4.9 m/sec) when the valve is in the fully open position. 1.1.1  Sizes.  This standard describes nonrising stem resilient seated gate valves 3-in. (75-mm) NPS* through 48-in. (1,200-mm) NPS and outside screw and yoke (OS&Y) rising stem valves, 3-in. (75-mm) NPS through 16-in. (400-mm) NPS. Sizes refer to the nominal diameter of the waterway through the inlet and outlet connections and the closure area. 1.1.2  Valve pressure rating.  The minimum design working water pressure shall be 200 psig (1,380 kPa) for all sizes. 1.1.3  Conditions and materials not covered.  This standard is not intended to describe special conditions of gate valve installation or operation,



* Nominal pipe size. 1 Copyright © 2009 American Water Works Association. All Rights Reserved.

2  AWWA C515-09

such as built‑in power drive, installation in unusually corrosive soil, conveyance of unusually corrosive water, excessive water hammer, frequent operation (as in filter service), or operation in a throttled position. These conditions are beyond the intended scope of this standard and require special consideration in design and construction. Joint accessories for end connections, such as bolts, gaskets, glands, and follower rings, are not described in this standard.

Sec. 1.2

Purpose The purpose of this standard is to provide purchasers, manufacturers, and suppliers with the minimum requirements for reduced-wall, resilient-seated gate valves for water supply service, including materials, design, testing, inspection, rejection, marking, and shipping.

Sec. 1.3

Application This standard can be referenced in specifications for purchasing and receiving reduced-wall, resilient-seated gate valves for water supply service. The stipulations of this standard apply when this document has been referenced and then only to reduced-wall, resilient-seated gate valves for water supply service.

Section  2: REFERENCES This standard references the following documents. In their latest editions, they form a part of this standard to the extent specified within this standard. In any case of conflict, the requirements of this standard shall prevail. ANSI*/AWWA  C110/A21.10—Ductile-Iron and Gray-Iron Fittings for Water. ANSI/AWWA  C111/A21.11—Rubber-Gasket Joints for Ductile-Iron Pressure Pipe and Fittings. ANSI/AWWA C153/A21.53—Ductile-Iron Compact Fittings, 3 In. Through 64 In. (76 mm Through 1,600 mm), for Water Service. ANSI/AWWA C550—Protective Interior Coatings for Valves and Hydrants. ANSI/AWWA C600—Installation of Ductile-Iron Water Mains and Their Appurtenances. ANSI/SAE† AS-568A—Aerospace Size Standard for O-Rings.



* American National Standards Institute, 25 West 43rd Street, Fourth Floor, New York, NY 10036. † SAE International, 400 Commonwealth Drive, Warrendale, PA 15096.

Copyright © 2009 American Water Works Association. All Rights Reserved.

Reduced-Wall, resilient-Seated gate valves for water supply Service  3

ASME* B16.1—Cast Iron Pipe Flanges and Flanged Fittings, Class 25, 125, and 250. ASME B16.10—Face‑To‑Face and End‑To‑End Dimensions of Valves. ASME  B18.2.1—Square and Hex Bolts and Screws Inch Series Including Hex Cap Screws and Lag Screws. ASTM† A27—Standard Specification for Steel Castings, Carbon, for General Applications. ASTM  A126—Standard Specification for Gray Iron Castings for Valves, Flanges, and Pipe Fittings. ASTM A153/A153M—Standard Specification for Zinc Coating (Hot‑Dip) on Iron and Steel Hardware. ASTM A276—Standard Specification for Stainless and Heat Resisting Steel Bars and Shapes. ASTM  A307—Standard Specification for Carbon Steel Bolts and Studs, 60,000 PSI Tensile Strength. ASTM A380—Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment, and Systems. ASTM  A395/A395M—Standard Specification for Ferritic Ductile Iron Pressure‑Retaining Castings for Use at Elevated Temperatures. ASTM A473—Standard Specification for Stainless and Heat-Resisting Steel Forgings. ASTM A536—Standard Specification for Ductile Iron Castings. ASTM  A582—Standard Specification for Free Machining Stainless Steel Bars. ASTM A743—Standard Specification for Castings, Iron-Chromium, IronChromium-Nickel, Corrosion Resistant, for General Application. ASTM B16/B16M—Standard Specification for Free-Cutting Brass Rod, Bar and Shapes for Use in Screw Machines. ASTM  B62—Standard Specification for Composition Bronze or Ounce Metal Castings. ASTM  B98—Standard Specification for Copper-Silicon Alloy Rod, Bar, and Shapes.



* ASME International, Three Park Avenue, New York, NY 10016. † ASTM International, 100 Barr Harbor Drive, West Conshohocken, PA 19428.

Copyright © 2009 American Water Works Association. All Rights Reserved.

4  AWWA C515-09

ASTM B124/B124M—Standard Specification for Copper and Copper Alloy Forging Rod, Bar, and Shapes. ASTM B138—Standard Specification for Manganese Bronze Rod, Bar, and Shapes. ASTM B148—Standard Specification for Aluminum-Bronze Sand Castings. ASTM B154—Standard Test Method of Mercurous Nitrate Test for Copper and Copper Alloys. ASTM  B283—Standard Specification for Copper and Copper-Alloy Die Forgings (Hot Pressed). ASTM B584—Standard Specification for Copper Alloy Sand Castings for General Applications. ASTM  B633—Standard Specification for Electrodeposited Coatings of Zinc on Iron and Steel. ASTM B763—Standard Specification for Copper Alloy Sand Castings for Valve Application. ASTM B824—Standard Specification for General Requirements for Copper Alloy Castings. ASTM D395—Standard Test Methods for Rubber Property—Compression Set. ASTM D429—Standard Test Methods for Rubber Property—Adhesion to Rigid Substrates. ASTM  D471—Standard Test Method for Rubber Property—Effect of Liquids. ASTM D1149—Standard Test Method for Rubber Deterioration—Surface Ozone Cracking in a Chamber (Flat Specimen). ASTM  D2000—Standard Classification System for Rubber Products in Automotive Applications. ASTM  D5363—Standard Specification for Anaerobic Single-Component Adhesives (AN). AWWA Manual M27—External Corrosion: Introduction to Chemistry and Control. Fed. Spec.* HH‑P‑106d—Packing; Flax or Hemp.



* Federal Specifications are available from Naval Publications and Form Center, 5801 Tabor Ave., Philadelphia, PA 19120.

Copyright © 2009 American Water Works Association. All Rights Reserved.

Reduced-Wall, resilient-Seated gate valves for water supply Service  5

MSS* SP‑9—Standard Practice for Spot Facing for Bronze, Iron, and Steel Flanges. MSS SP-60—Standard Practice for Connecting Flange Joint Between Tapping Sleeves and Tapping Valves. MSS  SP-113—Standard Practice for Connecting Joint Between Tapping Machines and Tapping Valves.

Section  3: DEFINITIONS The following definitions shall apply in this standard: 1.  Antiseize compound:  An anaerobic adhesive suitable for locking, sealing, and retaining threaded or cylindrical assemblies per ASTM D5363, or a compound that enables nondestructive assembly and disassembly of threaded components. 2.  Cosmetic defect:  Blemishes that have no effect on the ability of the component to meet the structural design and production test requirements of this standard. Should the activity of plugging, welding, grinding, or repairing of the blemish cause the component to fail these requirements, the blemish may not be considered a cosmetic defect. 3.  Flanged joint:  The flanged and bolted joint as described in ANSI/AWWA C110/A21.10 or ASME B16.1, Class 125, or Sec. 4.4.1.4.1 of this standard. 4.  Manufacturer:  The party that manufactures, fabricates, or produces materials or products. 5.  Mechanical joint:  The gasketed and bolted joint as described in ANSI/AWWA C110/A21.10, ANSI/AWWA C111/A21.11, or ANSI/AWWA C153/ A21.53. 6.  NPS:  Nominal pipe size. 7.  Purchaser:  The person, company, or organization that purchases any materials or work to be performed. 8.  Push-on joint:  The single rubber-gasket joint as described in ANSI/ AWWA C111/A21.11. 9.  Structural defect:  Flaws that cause the component to fail the



* Manufacturers Standardization Society of the Valve and Fittings Industry, 127 Park Street NE, Vienna, VA 22180.

Copyright © 2009 American Water Works Association. All Rights Reserved.

6  AWWA C515-09

structural design or test requirements of this standard. This includes but is not limited to imperfections that result in leakage through the walls of a casting, failure to meet the minimum wall thickness requirement, or failure to meet production tests. 10.  Supplier:  The party that supplies materials or services. A supplier may or may not be the manufacturer. 11.  Tapping valve:  A special gate valve designed with end connections and an unobstructed waterway to provide proper alignment and positioning of a tapping sleeve, valve, and machine for tapping pipe dry or under pressure.

Section  4: REQUIREMENTS Sec. 4.1

Data to Be Supplied by the Manufacturer If requested by the purchaser, the manufacturer or supplier shall provide the following information when supplying reduced-wall, resilient-seated gate valves: 4.1.1  Catalog data.  Catalog data, including illustrations and a parts list that identifies the materials used for various parts. The information shall be in sufficient detail to serve as a guide in the assembly and disassembly of the valve and for ordering repair parts. 4.1.2  Weight information  Net assembled weight for each size of valve exclusive of joint accessories. 4.1.3  Assembly drawings.  One set of drawings showing the principal dimensions, construction details, and materials used for valve parts. Work shall be done and valves shall be provided in accordance with these drawings after the drawings have been reviewed and accepted by the purchaser.

Sec. 4.2

Materials Materials shall comply with the requirements of the Safe Drinking Water Act and other federal regulations for potable water, wastewater systems, and reclaimed water as applicable. 4.2.1  General.  Materials used in valves produced according to this standard shall conform to the requirements stipulated in the following sections. 4.2.2  Dissimilar metals.  In the presence of an electrolyte, direct contact between metals of dissimilar corrosion resistance may result in galvanic corrosion of the more active, less corrosion-resistant material. When dissimilar metals must be used for internal parts, the rate of corrosion shall be reduced as much as practicable through the selection of materials that exhibit similar resistance to corrosion, by

Copyright © 2009 American Water Works Association. All Rights Reserved.

Reduced-Wall, resilient-Seated gate valves for water supply Service  7

placing a dielectric material between metals or applying a dielectric coating. When contact between dissimilar metals cannot be avoided, the assembly shall be designed so that the resulting corrosion will be minimized and will not adversely affect water quality or result in malfunctioning or premature failure of the assembly. 4.2.3  Physical and chemical properties.  The requirements of AWWA, ANSI, ASTM, or other standards referenced in this text shall govern the physical and chemical characteristics of the valve components. Whenever valve components are to be made in conformance with AWWA, ANSI, ASTM, or other standards that include test requirements or testing procedures, the manufacturer or supplier shall comply with those procedures. Records of tests performed shall, if required by the purchase documents, be made available to the purchaser. 4.2.3.1  Gray iron.  Gray iron shall conform to or exceed the requirements of ASTM A126, Class B. 4.2.3.2  Ductile iron.  Ductile iron shall conform to the requirements of ASTM A395 or ASTM A536. In addition, ductile iron shall contain no more than 0.08 percent phosphorus. 4.2.3.3  Copper alloys.  Copper alloys used in valves shall comply with the following: 4.2.3.3.1  Copper alloy valve components shall be made to ASTMrecognized alloy specifications in the Metals and Alloys in the Unified Numbering System (UNS)* designations. Copper alloys are not limited to those specified in this standard. Copper alloys, however, must meet the performance requirements of this standard, including, but not limited to, minimum yield strength, chemical requirements, and corrosion resistance. 4.2.3.3.2  Any copper alloy used in the cold‑worked condition shall be capable of passing the mercurous nitrate test in accordance with ASTM B154 to minimize susceptibility to stress corrosion. 4.2.3.3.3  Waters in some areas have been shown to promote corrosion in the form of dezincification or dealuminization of copper alloys. The manufacturer should be notified if this condition exists. Copper alloys that contain more than 16 percent zinc shall not be used in these waters. If aluminum bronze is used, the alloys shall be inhibited against dealuminization. 4.2.3.3.4  Copper alloys that contain more than 16 percent zinc shall not contain less than 57 percent copper.



* Joint publication of ASTM and SAE (ASTM DS56J/SAE HS-1086, 2008).

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8  AWWA C515-09

4.2.3.3.5  Copper alloys that contain 16 percent or less zinc shall not contain less than 79 percent copper. 4.2.3.3.6  Valve components manufactured from some grades of manganese, bronze, or some other materials are subject to stress corrosion. The manufacturer shall design the valve and select materials to minimize stress corrosion. 4.2.3.3.7  Copper alloys that contact drinking water shall comply with the Safe Drinking Water Act. 4.2.3.4  Carbon steel.  Carbon steel castings, when used, shall conform to the requirements of ASTM A27 Grade U-60-30 or equal. 4.2.3.5  Stainless steel.  Stainless steel used in valves shall comply with the following: 4.2.3.5.1  The chemical composition of stainless-steel valve components shall contain not less than 15 percent chromium or more than 0.25 percent carbon and shall be processed to reduce the formation of chromium carbides. 4.2.3.5.2  Stainless-steel valve components, when used, shall be made to ASTM recognized alloy specifications with metal and alloys in the Unified Numbering System (UNS). Stainless-steel alloys are not limited to those specified herein. Stainless-steel alloys, however, must meet the performance requirements of this standard including, but not limited to, the minimum yield strength and chemical requirements. 4.2.3.5.3  After final forming and machining, exogenous iron shall be removed from finished stainless-steel components that come in contact with water, or those components shall be passivated in accordance with ASTM A380. Other stainless-steel components shall be cleaned and descaled per the manufacturer’s requirements. 4.2.3.6  Gaskets.  Gasket material shall be made of inorganic mineral fiber, rubber composition, or paper that is free from corrosive ingredients. O‑rings or other suitable elastomeric seals may be used. 4.2.3.7  O-rings.  O-rings shall meet the requirements of ASTM D2000 and have physical properties suitable for the application. 4.2.3.8  Coatings.  Unless otherwise specified by the purchaser, valve coatings, as required in Sec.  4.5.2, shall be water-based enamel coating, black asphalt coatings, ANSI/AWWA  C550 coatings, or equal except as required by Sec. 4.4.1.3. 4.2.3.9  Elastomers.  Elastomers shall comply with the following: a.  Rubber seats shall be resistant to microbiological attack, copper poison-

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Reduced-Wall, resilient-Seated gate valves for water supply Service  9

ing, and ozone attack. b.  Rubber-seat compounds shall contain no more than 8 parts per million (ppm) of copper ion and shall include copper inhibitors to prevent copper degradation of the rubber material. c.  Rubber-seat compounds shall be capable of withstanding an ozone resistance test when tested in accordance with ASTM  D1149. The tests shall be conducted on unstressed samples for 70  hr at 104°F (40°C) with an ozone concentration of 500 parts per billion (ppb) without visible cracking in the surfaces of the test samples after a test. d.  Rubber-seat compounds shall have a maximum compression set value of 20 percent when tested in accordance with ASTM D395, method B, for 22 hr at 158°F (70°C). e.  Rubber-seat compounds shall contain no more than 1.5 parts of wax per 100 parts of rubber hydrocarbon and shall have less than 2 percent volume increase when tested in accordance with ASTM  D471 after being immersed in distilled water at 73.4°F ± 2°F (23°C ± 1°C) for 70 hr. Reclaimed rubber shall not be used. f.  Rubber-seat compounds shall be free of vegetable oils, vegetable oil derivatives, animal fats, and animal oils.

Sec. 4.3

General Design 4.3.1  Structural design.  Valve parts shall be designed to withstand (1) an internal test pressure of twice the rated design working pressure of the valve; and (2) the full‑rated internal working pressure when the closure member is cycled once from a fully open to a fully closed position against the full‑rated unbalanced working water pressure. In addition to these pressure requirements, the valve assembly and mechanism shall withstand a stem torque shown in Table 1. 4.3.2  Size of waterway.  With the valve open, an unobstructed waterway shall be provided. The waterway shall have a diameter equal to or larger than the full nominal diameter of the valve. For tapping valves, the size of the waterway

Table 1 Design torque Nominal Valve Size or NPS

Design Torque

in.

(mm)

ft-lb

(Nm)

3–4

(75–100)

200

(270)

6–16

(150–400)

300

(406)

Larger than 16

(400)

Consult Manufacturer

Copyright © 2009 American Water Works Association. All Rights Reserved.

10  AWWA C515-09

shall include appropriate clearance for the diameter of the tapping machine cutter recommended by the valve manufacturer.

Sec. 4.4

Detailed Design 4.4.1  Body and bonnet. 4.4.1.1  Material.  The body and bonnet shall be made of ductile iron. 4.4.1.2  Shell thickness.  Shell thickness at no point shall be less than the minimum metal thickness shown in Table 2. 4.4.1.3  Body seating surfaces.  Resilient seats shall seal against a corrosionresistant surface. The surface may be either metallic or nonmetallic, applied in a manner to withstand the action of the line fluids and the operation of the sealing gate during long-term service. A metallic surface shall have a corrosion resistance equivalent to or better than bronze. A nonmetallic surface shall be in compliance with ANSI/AWWA C550. 4.4.1.4  Valve ends.  Except as agreed on by the purchaser and supplier, end connections shall conform to one of the following requirements. 4.4.1.4.1  The thickness of the end flanges may be less than specified in ASME B16.1 or ANSI/AWWA C110/A21.10 but not less than shown in Table 4. Other dimensions and drilling of end flanges shall conform to ASME B16.1 class 125 or ANSI/AWWA C110/A21.10 except as modified by the purchase documents. Unless spot‑facing is required by the purchase documents, the bolt holes of the end flanges shall not be spot‑faced except when the thickness at any point within the spot‑face area, as defined in MSS SP‑9, exceeds the required minimum flange thickness of ASME B16.1 by more than indicated in Table 3 or if the flange is not sufficiently flat. If the foregoing limit is exceeded, either spot‑facing or backfacing may be used to meet the requirements. When required, spot‑facing shall be done in accordance with MSS SP‑9. Bolt holes shall straddle the vertical centerline of the valve, unless otherwise specified by the purchaser. The laying lengths of flanged valves 12 in. (300 mm) and smaller shall conform to the requirements for double disc gate valves listed in Table 1 of ASME B16.10. 4.4.1.4.2  Mechanical-joint bell dimensions shall conform to ANSI/AWWA C111/A21.11. Slots with the same width as the diameter of the bolt holes may be provided instead of holes in the bell flange where the valve body and bonnet interfere with the joint assembly. 4.4.1.4.3  Push‑on joints shall conform to the requirements of ANSI/ AWWA C111/A21.11.

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Reduced-Wall, resilient-Seated gate valves for water supply Service  11

Table 2 Minimum thickness of body and bonnet Nominal Valve Diameter Size or NPS in. (mm) 3 4 6 8 10 12 14 16 18 20 24 30 36 42 48

(75) (100) (150) (200) (250) (300) (350) (400) (450) (500) (600) (750) (900) (1,050) (1,200)

Minimum Metal Thickness in. (mm) 0.30 0.31 0.32 0.34 0.36 0.38 0.45 0.50 0.56 0.56 0.62 1.06 1.31 1.42 1.44

(7.6) (7.9) (8.1) (8.6) (9.1) (9.7) (11.4) (12.7) (14.2) (14.2) (15.7) (26.9) (33.3) (36.0) (39.6)

Table 3 Excess flange thickness Nominal Valve Size or NPS

Excess Thickness (maximum)

in.

(mm)

in.

(mm)

03–12 14–24 30–48

0(75–300) (350–600) (750–1,200)

⅛ 3⁄₁₆

(3.2) (4.8) (6.4)

¼

Table 4 Minimum thickness for ductile-iron connecting end flanges Nominal Valve Size or NPS

Flange Thickness

in.

(mm)

in.

(mm)

4 6 8 10 12 14 16 18 20 24 30 36 42 48

(100) (150) (200) (250) (300) (350) (400) (450) (500) (600) (750) (900) (1,050) (1,200)

¾ ¾ ⅞ ¹⁵⁄₁₆ 1 1 1 1 1⅛ 1 3⁄₁₆ 1⅜ 1¾ 2 2⅛

(19.1) (19.1) (22.2) (23.8) (25.4) (25.4) (25.4) (25.4) (28.6) (30.1) (34.9) (44.5) (50.8) (54.0)

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12  AWWA C515-09

4.4.1.4.4  The end flange of a tapping valve that forms a joint with the tapping sleeve shall conform to the dimensions of MSS SP-60 in sizes 3-in. (75-mm) through 12-in. (300-mm) NPS. For larger sizes, flange dimensions shall be as agreed to by the purchaser and supplier. The connecting flange of the tapping valve mating with the tapping machine must be parallel and concentric with the opposite flange and concentric with the waterway to provide proper alignment for the tapping operation. The end flange of a tapping valve that forms a joint with the tapping machine shall conform to the dimensions of MSS SP-113. 4.4.1.5  Yokes on OS&Y valves.  On OS&Y valves, the yoke on bonnets may be integral or of bolted‑on construction. If the yoke is not an integral part of the bonnet, it shall be made of ductile iron or gray iron. The design shall be such that a hand cannot be jammed between a yoke and the handwheel. 4.4.2  Gate. 4.4.2.1  Material.  The material of the gate shall be ductile iron, gray iron, or copper alloy (see Table 5 for copper alloys). 4.4.2.1.1  Resilient seats shall be bonded or mechanically attached to the gate. The proof-of-design test method used for bonding or vulcanizing shall be ASTM D429—either method A or method B. For method A, the minimum strength shall not be less than 250 psi (1,725 kPa). For method B, the peel strength shall not be less than 75 lb/in. (13.2 N/mm). Exposed mechanical attaching devices and hardware used to retain the resilient seat shall be of a corrosion-resistant material. 4.4.3  Guides.  If guiding is required to obtain shutoff, the design shall be such that corrosion in the guide area does not affect seating. 4.4.4  Bolting.  Bolting materials, excluding joint accessories, shall meet the mechanical strength requirements of ASTM A307 and shall have either regular square, hexagonal, or socket heads with dimensions conforming to ASME B18.2.1, B18.2.3.1M, B18.3, or B18.3.1M. Bolts, studs, and nuts shall be (1)  zinc‑coated (ASTM  A153 or B633); or (2)  made corrosion-resistant by some other process disclosed to and acceptable to the purchaser. The purchaser may specify bolts, studs, and nuts made from a specified corrosion-resistant material, such as low‑zinc bronze, nickel-copper alloy, or stainless steel. Stainless-steel bolts and studs shall not be used on stainless nuts unless the threads are coated with an antiseize compound or the fastening components are made of different alloys or some other means are used to prevent galling.

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Reduced-Wall, resilient-Seated gate valves for water supply Service  13

Table 5 Stem, gate, thrust collar, and stem nut copper alloys Copper Alloy*

Stems, Gates, and Thrust Collars

ASTM Specification Number ASTM B16 ASTM B138 ASTM B283 ASTM B98 ASTM B148 ASTM B584

ASTM B763

Stem Nuts and Gates

Alloy Designation UNS C36000 UNS C67500 UNS C67600 UNS C66100 UNS C86200 UNS C95200 UNS C95300 UNS C95500 UNS C865002 UNS C86700† UNS C87500 UNS C87600 UNS C87610 UNS C86500† UNS C86700† UNS C99400 UNS C99500

ASTM B62 ASTM B824 ASTM B124 ASTM B148

UNS C83600 UNS C84400† UNS C37700 UNS C95200 UNS C95300 UNS C95500

ASTM B584

UNS C84400† UNS C83450 UNS C86700† UNS C87500 UNS C87610 UNS C86500† UNS C86700† UNS C95200 UNS C95500 UNS C95800 UNS C99400 UNS C99500

ASTM B763

* Alloys actually used or specified not limited to those listed—see Sec. 4.2.3.3.1. † Compliance with ANSI/AWWA C515 requires the manufacturer to specify minimum mechanical (yield strength) or chemical (copper and/or zinc) requirements that exceed the minimums required for this alloy by the ASTM specification(s) listed.

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14  AWWA C515-09

Table 6 Stainless-steel valve stem alloys Specification Number

Alloy Designation*

ASTM A276 ASTM A276 ASTM A276 ASTM A473 ASTM A473 ASTM A582 ASTM A743/A743M ASTM A743/A743M

UNS S30400 UNS S31600 UNS S43100 UNS S30400 UNS S31600 UNS S43020 CF8 J92600 CF8M J92900

* Alloys actually used or specified not limited to those listed—see Sec. 4.2.3.5.

4.4.4.1  Recessed sockets.  Recessed socket in bolts shall be plugged and/ or sealed. 4.4.5  Stem, stem nut, and thrust collar. 4.4.5.1  Alloy.  Copper alloy stems, stem nuts, thrust collar, and gates shall be made from an alloy listed in Table  5. Stainless-steel stems shall be made from an alloy listed in Table 6. When stainless-steel stems are used, the stem, stem nut, and thrust collar materials shall be selected to prevent galling when subjected to the torques given in Table 10. 4.4.5.1.1  Valve stems shall have a yield strength of 20,000 psi (137,800 kPa) or greater. 4.4.5.2  Stem nuts.  Stem nuts shall be made from copper alloys that have a yield strength of 14,000 psi (96,500 kPa) or greater (see Table  5). 4.4.5.3  NRS stems.  The stem must have a thrust collar that shall be integral or nonintegral with the stem. 4.4.5.4  OS&Y stems.  OS&Y valve stems shall be of sufficient length so as to be at least flush with the top of the stem nut after the gate is fully closed. The design shall prevent any possibility of the gate leaving the stem or the stem turning during the operation of the valve. 4.4.5.5  Threads.  The threads of stems and stem nuts shall be of Acme, modified Acme, stub Acme, or one‑half V type. Stems and stem nuts shall be threaded straight and true and shall work true and smooth throughout the lift of opening and thrust of closing the valve. 4.4.5.6  Diameter.  The stem diameters and turns to open shall be as shown in Table 7.

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Reduced-Wall, resilient-Seated gate valves for water supply Service  15

Table 7 Minimum diameter of stem and minimum number of turns to open Valve Size or NPS

NRS Valves

Minimum Diameter of Stem* in.

(mm)

in.

(mm)

03 04 06 08 10 12 14 16 18 20 24 30 36 42 48

0(75) (100) (150) (200) (250) (300) (350) (400) (450) (500) (600) (750) (900) (1,050) (1,200)

0.859 0.859 1.000 1.000 1.125 1.188 1.250 1.438 1.625 1.750 1.969 2.188 2.500 2.750 3.430

(21.82) (21.82) (25.40) (25.40) (28.58) (30.18) (31.75) (36.53) (41.28) (44.45) (50.01) (55.58) (63.50) (69.85) (87.12)

OS&Y Valves

Minimum Number of Turns of Stem to Open 09 12 18 24 30 36 42 48 54 40 48 60 72 84 96

Minimum Diameter of Stem Unthreaded Section and Thread OD† in.

(mm)

0¾ 1 ¾ 1⅛  1¼ 1⅜ 1⅜ 1⁷⁄₁₆ 1½

(19.1) (25.4) (28.6) (31.8) (34.9) (34.9) (36.5) (38.1)

Minimum Number of Turns of Stem to Open‡ 07 09 18 25 31 37 42 48

* The diameter of the stem at the base of the thread or at any point below that portion shaped to receive the wrench nut on NRS valves or the minimum diameter of the stem unthreaded section and thread OD for OS&Y valves shall not be less than specified. † Outside diameter. ‡ Valves shown for 6–12-in. NPS sizes are for single-lead threads. If a double-lead thread is used, minimum turns become 13, 17, 21, and 25 for sizes 6–12-in. NPS inclusive.

4.4.6  Stem sealing.  The sealing system shall be designed to be watertight at the rated working pressure of the valve. 4.4.6.1  NRS valves.  4.4.6.1.1  A stem seal plate or O‑ring packing plate shall be made of ductile iron or gray iron. Stem openings, if bushed, or stem-seal cartridges, shall be of a copper alloy, or a synthetic polymer with physical properties suitable for the application. Stem-seal plate bolts and nuts shall conform to the requirements as specified in Sec. 4.4.4. 4.4.6.1.2  On NRS valves, the stem opening, thrust bearing recess, and bonnet face of the stem-seal plate shall be machined or finished in a manner that will provide surfaces that are smooth and either parallel or perpendicular to the stem axis within 0.5°.

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16  AWWA C515-09

4.4.6.1.3  When an O‑ring or other pressure‑actuated stem seal is used, the design shall incorporate at least two such seals. The dimensions of the O-rings shall be in accordance with SAE AS‑568A. 4.4.6.2  OS&Y valves. 4.4.6.2.1  A stuffing box shall be provided to contain stem packing. Stuffing-box packing shall be made of flax conforming to Fed. Spec. HH‑P‑106d or other appropriate material. Hemp, asbestos, or jute packing shall not be used. 4.4.6.2.2  Stuffing boxes shall have a depth not less than the diameter of the valve stem. The internal diameter shall be large enough to contain adequate packing to prevent leakage around the stem. 4.4.6.2.3  Stuffing boxes shall be packed properly and ready for service when valves are delivered to the purchaser. Stuffing-box bolts may need to be adjusted to stop leakage at the time of installation. 4.4.6.2.4  The packing gland assembly shall be of solid, solid‑bushed, or two‑piece design. Followers may be formed as a flanged end on the gland or as a separate item. 4.4.6.2.4.1  Packing glands shall be made of a copper alloy, synthetic polymer, gray iron, or ductile iron. 4.4.6.2.4.2  If a gland follower is used, it shall be made of either ductile or gray iron, or a copper alloy. 4.4.6.2.4.3  Gland bolts and nuts shall be according to Sec. 4.4.4. Glandbolt nuts shall be made of a copper alloy, or stainless steel. Stainless-steel nuts shall not be used on stainless-steel packing gland bolts unless the threads are coated with an antiseize compound or the fastening components are made of different alloys, or some other means is used that prevents galling. 4.4.6.3  Stem-seal replacement. 4.4.6.3.1  NRS valves shall be designed so that the seal above the stem collar can be replaced with the valve under pressure in the fully open position. 4.4.6.3.2  Design of OS&Y valves shall be such that the stuffing box can be packed when the valves are in the fully open position and under pressure. 4.4.7  Wrench nuts and handwheels.  Wrench nuts and handwheels shall be made of gray iron or ductile iron. Unless otherwise explicitly required by the purchase documents, the wrench nuts shall be 115/16 in. (49.2 mm) square at the top, 2 in. (50.8 mm) square at the base, and 1¾ in. (44.5 mm) high. The outside diameter of handwheels shall not be less than those given in Table 8. Nuts shall have a flanged base on which shall be cast an arrow at least 2 in. (50.8 mm) long

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Reduced-Wall, resilient-Seated gate valves for water supply Service  17

Table 8 Diameter of handwheels* Size of Valve or NPS

Minimum Diameter of Handwheel

in.

(mm)

in.

(mm)

3

(75)

7

(178)

4

(100)

10

(254)

6

(150)

12

(305)

8

(200)

14

(356)

10

(250)

16

(406)

12

(300)

16

(406)

* For sizes larger than 12 in. (300 mm), consult the manufacturer.

showing the direction of the opening. The word “OPEN,” in ½-in. (12.7‑mm) or larger letters, shall be cast on the nut to indicate clearly the direction to turn the wrench when opening the valve. Handwheels shall be of the spoke type only. Webbed or disc types are not permissible. An arrow showing the direction to turn the handwheel to open the valve, with the word “OPEN” in ½-in. (12.7-mm) or larger letters in a break in the arrow shaft, shall be cast on the rim of the handwheel so as to be read easily. 4.4.8.1  Operating mechanism.  NRS valves are to be supplied with wrench nuts or handwheels. OS&Y valves are to be supplied with handwheels. 4.4.8.2  Direction of opening.  The standard direction of opening is counterclockwise as viewed from the top. Valves opening in the opposite direction (clockwise) may be specified. 4.4.8.3  Method of securing.  Wrench nuts or handwheels shall be fitted to the valve stem on NRS valves. Handwheels shall be fitted to the stem nut on OS&Y valves. In both cases, they shall be secured by mechanical means. 4.4.8.4  Color coding.  Wrench nuts and handwheels that open the valve by turning to the right (clockwise) shall be painted red, and wrench nuts and handwheels that open the valve by turning to the left (counterclockwise) shall be painted black. 4.4.9  Gaskets.  Gaskets, O-rings, or other suitable elastomeric seals shall be used on flanged joints intended to be watertight. 4.4.10  Gearing.  If they are required by the purchase documents, gears shall be accurately formed and smooth running, with a pinion shaft operating in a bronze, self-lubricating, or permanently sealed antifriction bearing. 4.4.10.1  Material.  Geared valves shall be equipped with steel, ductile-iron,

Copyright © 2009 American Water Works Association. All Rights Reserved.

18  AWWA C515-09

or gray-iron gears. If cast-iron gears are provided, the pinion shall be steel. Material for steel gears shall be ASTM A27 Grade U-60-30 or equal. 4.4.10.2  Gear cases.  Valves using O-ring or V-type stem seals may have the gear case attached directly to the valve. When geared valves are provided, enclosed gear cases are required unless definitely excluded by the purchaser’s requirements. 4.4.10.3  Indicators.  When required by the purchase documents, geared valves shall be equipped with indicators to show the position of the gate in relation to the waterway. 4.4.10.4  Gear ratio.  Gear ratios shall not be less than those shown in Table 9. 4.4.10.5  Input torque.  The maximum input torque shall be as recommended by the manufacturer.

Sec. 4.5

Fabrication 4.5.1  Workmanship. 4.5.1.1  Interchangeable parts.  Valve parts shall conform to their required dimensions and shall be free from defects that could prevent proper functioning of the valve. Like parts of valves of the same model and size produced by the same manufacturer shall be interchangeable. 4.5.1.2  Castings.  Castings shall be clean and sound without defects that will weaken their structure or impair their service. Plugging, welding, or repairing of cosmetic defects is allowed. Repairing of structural defects is not allowed unless agreed to by the purchaser. Repaired valves shall comply with the testing requirements of this standard. Repairs within the bolt circle of any flange face are not allowed. 4.5.2  Coating. 4.5.2.1  Interior ferrous surfaces.  A coating conforming to the performance requirements of ANSI/AWWA C550 shall be applied to the interior ferrous surfaces of the body and bonnet that are in contact with liquid. Other exposed interior ferrous surfaces except finished or bearing surfaces shall be coated with a material specified in Sec. 4.2.3.8. 4.5.2.2  Exterior ferrous surfaces.  A coating material as specified in Sec. 4.2.3.8 shall be applied to exterior ferrous surfaces.

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Reduced-Wall, resilient-Seated gate valves for water supply Service  19

Table 9 Gear ratios Nominal Valve Size or NPS

Minimum Gear Ratio

in.

(mm)

16–24

(400–600)

2:1

30–36

(750–900)

3:1

42–48

(1,050–1,200)

4:1

Section  5: VERIFICATION Sec. 5.1

Testing 5.1.1  Proof of design testing. 5.1.1.1  Hydrostatic gate test.  One prototype valve of each size and class of the manufacturer’s design shall be hydrostatically tested with twice the specified rated pressure applied to one side of the gate and zero pressure on the other side. The test is to be made in each direction across the gate for a minimum period of 5 min. The manufacturer may make special provisions to prevent leakage past the seats. No part of the valve or gate shall remain visually deformed by the test. 5.1.1.2  Torque test.  A prototype of each size shall be overtorqued in the closed and open positions to demonstrate that no distortion of the valve stem or thrust collar or damage to the resilient seat occurred as evidenced by the failure to seal at the rated pressure. The torque applied to the main valve stem shall be in accordance with Table 10. For valves using stainless-steel stems, upon disassembly, there shall be no visible evidence of galling on the stem, thrust collar, or stem nut after completion of the torque test. 5.1.1.3  Leakage test.  One prototype valve of each size shall be fully opened and closed to a seal for 500 complete cycles with sufficient flow that the valve is at the rated working pressure for the pressure differential at the point of closing. The valves shall be drip-tight under the rated pressure differential applied alternately to each side of the gate after the completion of the tests. 5.1.1.4  Hydrostatic shell test.  One prototype of each valve size shall be tested to 2.5 times the rated working pressure with the gate in the open position. For a period of 5 min, there shall be no rupture or cracking of the valve body, valve bonnet, or seal plate. Leakage at pressure‑containing joints shall not be a cause for failure of the test. No part of the valve shall remain visibly deformed after the test.

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20  AWWA C515-09

Table 10 Proof of design torque Nominal Valve Size or NPS

Design Torque

in.

(mm)

ft-lb

(Nm)

3–4 6–12 14–24 30 36 42 48

(75–100) (150–300) (350–600) (750) (900) (1,050) (1,200)

250 350 400 500 600 700 800

(340) (475) (545) (680) (820) (950) (1,100)

5.1.2  Production testing.  After manufacture, each gate valve shall be subjected to operation and hydrostatic tests at the manufacturer’s plant as specified in this section. 5.1.2.1  Operation test.  Each valve shall be operated through a complete cycle to ensure proper functioning of parts. Any defects in workmanship shall be corrected, and the test repeated until a satisfactory performance is demonstrated. 5.1.2.2  Shell test.  A hydrostatic test pressure equal to twice the rated working pressure of the valve shall be applied to the assembled valve with the gate in the open position. The test shall show no leakage through the metal, pressurecontaining joints, or stem seals. 5.1.2.3  Seat test.  A hydrostatic test shall be made from each direction at a minimum of the rated working pressure to prove the sealing ability of each valve from both directions of flow. The test shall show no leakage through the metal, pressure‑containing joints, or past the seat.

Sec. 5.2

Plant Inspection and Rejection Work performed according to this standard, except prototype testing, shall be subject to inspection and acceptance by the purchaser, who shall have access to places of manufacture where these valves are being produced and tested. Any valve or part that may be determined as not conforming to the requirements of this standard shall be made satisfactory, or it shall be rejected and repaired or replaced by the manufacturer. Repaired valves must be acceptable to the purchaser and specifically accepted when submitted or resubmitted. Whether the purchaser has a representative at the plant or not, an affidavit of compliance may be required from the manufacturer as provided in Sec. 6.3 of this standard.

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Reduced-Wall, resilient-Seated gate valves for water supply Service  21

Section  6: DELIVERY Sec. 6.1

Marking Markings shall be cast on the bonnet or body, or stamped on a permanently affixed corrosion-resistant tag of each valve. Markings shall show the manufacturer’s name or mark, the year the valve casting was made, the size of the valve, letters “C515,” and the designation of working water pressure, for example, “200W.” Special markings in addition to these can be supplied when specified by the purchaser’s requirements on agreement between purchaser and manufacturer.

Sec. 6.2

Preparation for Shipment Valves shall be complete in detail when shipped. Valves shall be drained before shipment. Handwheels and valve accessories may be packed separately.

Sec. 6.3

Affidavit of Compliance The manufacturer shall, when required by the purchase documents, provide the purchaser with an affidavit stating that the valve and materials used in its construction conform to the applicable requirements of this standard and the purchase documents and that tests specified in this standard have been performed and test requirements have been met.

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APPENDIX A Installation, Operation, and Maintenance of Reduced-Wall, Resilient-Seated Gate Valves This appendix is for information only and is not a part of ANSI/AWWA C515.

Section A.1:

GENERAL

Resilient-seated gate valves form a significant component part of many firefighting or water‑distribution systems. Failure of a resilient-seated gate valve in these systems, either as a result of faulty installation or improper maintenance, could result in extensive damage and costly repairs. In addition, many resilientseated gate valves are installed in buried-service or underground applications. Problems or malfunctions of the valves because of faulty installation or improper maintenance can result in extensive and costly unearthing operations to effectively correct or eliminate the problem. Many resilient-seated gate-valve problems and failures can be traced back to improper handling, storage, installation, operation, or maintenance procedures.

Section A.2:

UNLOADING

Valves should be unloaded carefully. Each valve should be carefully lowered from the truck to the ground; it should not be dropped. In the case of larger valves, forklifts or slings around the body of the valve or under the skids should be used for unloading. Only hoists and slings with adequate load capacity to handle the weight of the valve or valves should be used. Hoists should not be hooked into or chains fastened around yokes, gearing, motors, cylinders, or handwheels. Failure to carefully follow these recommendations is likely to result in damage to the valve.

Section A.3:

RECEIVING INSPECTION

Resilient-seated gate valves should be inspected at the time of receipt for damage during shipment. The initial inspection should verify compliance with specifications, direction of opening, size and shape of operating nut, number of turns to open or close, and type of end connections. A visual inspection of the seating 23 Copyright © 2009 American Water Works Association. All Rights Reserved.

24  AWWA C515-09

surfaces should be performed to detect any damage during shipment or scoring of the seating surfaces. Inspection personnel should look for bent stems, broken handwheels, cracked parts, loose bolts, missing parts and accessories, and any other evidence of mishandling during shipment. Each valve should be operated through one complete opening‑and‑closing cycle in the position in which it is to be installed.

Section A.4:

STORAGE

Valves should be stored indoors. If outside storage is required, the valves should be protected from weather elements. During outside storage, they should be protected from the weather, sunlight, ozone, and foreign materials. In colder climates where valves may be subject to freezing temperatures, it is absolutely essential to prevent water from collecting in the valves. Failure to do so may result in a cracked valve casting or deterioration of the resilient seat material.

Section A.5:

INSTALLATION

Instructions supplied by manufacturers should be reviewed in detail before valves are installed. At the job site prior to installation, each valve should be visually inspected and any foreign material in the interior portion of the valve should be removed. A detailed inspection of the valve as outlined in Sec. A.3 should be performed prior to installation.

Sec. A.5.1 Bolts Bolts should be checked for proper tightness and protected by the installer to prevent corrosion, either with a suitable paint or by polyethylene wrapping or other suitable means of corrosion protection.

Sec. A.5.2 Underground Installation Valves in water-distribution lines shall, where practical, be located in easily accessible areas. A.5.2.1  During installation, there is the possibility of foreign materials inadvertently entering the valve. Foreign material can damage internal working parts during operation of the gate valve. For this reason, gate valves should be installed in the closed position. Each valve should be placed on firm footing in the trench to prevent settling and excessive strain on the connection to the pipe. Piping systems should be supported and aligned to avoid damage to the valve.

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Reduced-Wall, resilient-Seated gate valves for water supply Service  25

A.5.2.2  A valve box or vault should be provided for each valve used in a buried-service application. The valve box should be installed so as not to transmit loads or stress to the valve, valve stem, or piping system. The valve box should be centered over the operating nut of the valve with the box cover flush with the surface of the finished area or another level as directed by the purchaser. Valve boxes should be designed so that a traffic load on the top of the box is not transmitted to the valve stem or piping system. A.5.2.3  Valves buried in unusually deep trenches have special provisions for operating the valve. These are either a riser on the stem to permit a normal key to be used or a notation on valve records that a long key will be required. A.5.2.4  When valves with exposed gearing or operating mechanisms are installed belowground, a vault designed to allow pipe clearance and prevent settling on the pipe should be provided. The operating nut should be accessible from the top opening of the vault with a valve key. The size of the vault should provide for easy removal of the valve bonnet and internal parts of the valve for purposes of repair. Consideration should be given to the possible entry of groundwater or surface water and to the need to provide for the disposal thereof.

Sec. A.5.3 Aboveground Installations Valves installed aboveground or in a plant piping system should be supported and aligned to avoid damage to the valve. Valves should not be used to correct misalignment of piping.

Sec. A.5.4 Inspection After installation and before pressurization of the valve, pressure‑containing bolting (bonnet, seal plate, packing gland, and end connections) should be inspected for adequate tightness to prevent leakage. In addition, an inspection should be made for adequate tightness of tapped and plugged openings to the valve interior. Proper inspection at this time will minimize the possibility of leaks after the piping system has been pressurized.

Sec. A.5.5 Testing To prevent time lost searching for leaks, it is recommended that valve excavations not be backfilled until pressure tests have been completed. After installation, it is desirable to test newly installed piping sections, including valves, at some pressure above the system design pressure. The test pressure should not exceed the rated working pressure of the valve. After the test, steps should be taken to relieve any trapped pressure in the body of the valve. The resilient-seated gate valve should not be operated in either the opening or closing direction at differential pressures above the rated working pressure. It should be noted that valves seat better at or near the

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26  AWWA C515-09

rated working pressure of the valve. In addition, wear or foreign material may damage valve seating surfaces and may cause leakage (See ANSI/AWWA C600).

Sec. A.5.6 Records Once the valve is installed, the valve location, size, make, type, date of installation, number of turns to open, direction of opening, and other information deemed pertinent should be entered on permanent records.

Sec. A.5.7 Application Hazards Resilient-seated gate valves should not be installed in applications or for service other than those recommended by the manufacturer. The following list of precautions is not inclusive but will help avoid some applications hazards. A.5.7.1  Resilient-seated gate valves should not be installed in lines where service pressure will exceed the rated working pressure of the valve. A.5.7.2  Resilient-seated gate valves should not be used for throttling service unless the design is specifically recommended for that purpose or accepted in advance by the manufacturer. A.5.7.3  Resilient-seated gate valves should not be used in applications that are exposed to freezing temperatures unless sufficient flow is maintained through the valve or other protection is provided to prevent freezing. A.5.7.4  Pipe, fittings, and valves installed in underground piping are generally joined with push-on or mechanical joints. These joints are considered unrestrained-type joints because no significant restraint against longitudinal separation is provided. Gate valves should not be installed at a dead end or near a bend in a pipeline without proper and adequate restraint to support the valve and prevent it from blowing off the end of the line. Rigid piping systems incorporating flanged valves are not recommended for buried service. Thrust blocks, restrained joints, or other means of restraint are needed on or adjacent to valves on pipelines or where unusual conditions exist, such as high internal pressures, adjacent fittings, or unsuitable soils. A.5.7.5  To prevent damage, 3-in. (75-mm) NPS and 4‑in. (100-mm) NPS, resilient-seated gate valves should not be operated with input torques greater than 200 ft·lb (270 Nm). Gate valves 6-in. (150-mm) NPS to 16-in. (400-mm) NPS should not be operated with input torques greater than 300 ft·lb (406 Nm). For valves larger than 16 in. (400 mm), consult the manufacturer.

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Reduced-Wall, resilient-Seated gate valves for water supply Service  27

Section A.6:

MAINTENANCE

Sec. A.6.1 Valve Exercising Each valve should be operated through a full cycle and returned to its normal position on a time schedule that is designed to prevent a buildup of tuberculation or other deposits that could render the valve inoperable or prevent a tight shutoff. The interval of time between operations of valves in critical locations or valves subjected to severe operating conditions should be shorter than for other less important installations, but it can be whatever time period is found to be satisfactory based on local experience. The number of turns required to complete the operation cycle should be recorded and compared with permanent installation records to ensure full gate travel. When using portable, auxiliary power actuators with input torque capacities exceeding the maximum operating torques recommended in Sec. A.5.7.5, extreme care should be taken to avoid applying excessive torque to the valve stem. If the actuator has a torque‑limiting device, it should be set below the values in Sec. A.5.7.5. If there is no torque‑limiting device, the recommended practice is to stop the power actuator three or four turns before the valve is fully opened or fully closed and complete the operation manually. Maintenance should be performed at the time a malfunction is discovered to avoid a return trip to the same valve or to prevent neglecting it altogether. A recording system should be adopted that provides a written record of valve location, condition, maintenance, and each subsequent inspection of the valve.

Sec. A.6.2 Inspection Each valve should be operated through one complete operating cycle. If the stem action is tight, the operation should be repeated several times until proper operation is achieved. With the gate in the partially open position, a visual inspection should be performed, where practical, to check for leakage at joints, connections, and areas of packing or seals. If leakage is observed, defective O‑rings, seals, gaskets, or end‑connection sealing members should be replaced. If the leakage cannot be corrected immediately, the nature of the leakage should be reported promptly to those who are responsible for repairs. If the valve is inoperable or irreparable, its location should be clearly established to prevent loss of time for repair crews. The condition of the valve and, if possible, the gate position should be reported to the personnel responsible for repairs. In addition, fire departments

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28  AWWA C515-09

and other appropriate municipal departments should be informed that the valve is out of service.

Sec. A.6.3 Record Keeping To carry out a meaningful inspection and maintenance program, it is essential that the location, make, type, size, and date of installation of each valve be recorded. Depending on the type of record-keeping system used, other information may be entered in the permanent record. When a resilient-seated gate valve is inspected, an entry should be made in the permanent record indicating date of inspection and condition of the valve. If repair work is necessary, it should be indicated, and, on completion of the work, the nature of the repairs and date completed should be recorded.

Section A.7:

REPAIRS

Leakage, broken parts, hard operation, and other major defects should be corrected by a repair crew as soon as possible after the defect is reported. If repairs are to be performed in the field, the repair crew should take a full complement of spare parts to the jobsite. Provisions should be made to isolate the defective valve from water pressure and relieve internal trapped pressure prior to performing any corrective maintenance. Disassembly of the valve should be accomplished in accordance with the procedure supplied by the manufacturer. After repair of the valve, the operating mechanism should be cycled through one complete operating cycle. With full line pressure applied to the valve in the open position, an inspection should be made to detect leakage in the areas around the seal plate, bonnet, packing gland, and body-end connections. A record should be made to indicate that the valve has been repaired and is in working condition. Any markings that the valve is inoperable should be deleted. In addition, fire departments and other appropriate municipal departments should be informed of the satisfactory repair of the valve.

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AWWA is the authoritative resource for knowledge, information, and advocacy to improve the quality and supply of water in North America and beyond. AWWA is the largest organization of water professionals in the world. AWWA advances public health, safety, and welfare by uniting the efforts of the full spectrum of the entire water community. Through our collective strength, we become better stewards of water for the greatest good of the people and the environment.

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