Spears TRUE UNION 2000 Series User manual
SSI #49 6/13/2014 SPECIFICATION SUBMITTAL INFORMATION
THE FOLLOWING INFORMATION IS CORRECT AS NOTED BY THE FOLLOWING
INFORMATION FROM THE LISTED DATA SOURCES.
SUBMITTED BY MISCOWATER
27101 BURBANK STE B
FOOTHILL RANCH, CA 92610
PHONE 949-458-5555
RICK BARTON
REFERENCE ORANGE COUNTY SANITATION DISTRICT
SLUDGE DEWATERING AND ODOR CONTROL AT PLANT NO. 1
W. M. Lyles JOB T-1113 MISCO JOB 0222VB
GRANT GOURLEY 714-962-6828
PROJECT P1-101
10598 Garfield Ave
FOUTAIN VALLEY, CA 92708
SCOPE SUPPLY OF PVC MOV BALL VALVES FOR IW SERVICE
TYPE PLASTIC FULL PORT MODULATING
REFERENCE SPECIFICATION 15106.2.4
SUBMITTING "OR EQUAL " TO THE NAMED MANUFACTURERS
MANUFACTURER SPEARS MANUFACTURING
15852 OLDEN STREET
SYLMAR,CA 91392
818-364-1611
VALVE
SPEC COMPARISON ITEM DESCRIPTION OF ITEM
15106.A..2.4.A.1 CONFORMS PVC BODY; BALL; STEM; ENDS
15106.A..2.4.A.2 CONFORMS UNION/FLANGED AS REQUIRED
15106.A..2.4.B.1 CONFORMS FLANGES ASME16.5 CL 150 AS REQUIRD
15106.A..2.4.B.2 CONFORMS RATING OF PVC AS REQUIRED
15106.A..2.4.B.3 CONFORMS BALL FULL PORT WITH TFE SEAT
15106.A..2.4.B.4 CLARIFICATION BODYBALL SEALS ARE TFE TFE HAS NO ENERGIZING FEATURE;
STEM BEARING IS TFE RESILIENT SEAT IS REQUIRED FOR SEALS
O-RING SEALS AND STEM RESILIENT SEAT IS REQUIRED FOR SEALS
ALTERNATE SEALS ARE MEDIA COMPATIBLE VITON
15106.A..2.4.B.5 CONFORMS FULL PORT
15106.A..2.4.B.6 CONFORMS NA
15106.C CONFORMS LIMITORQUE QX
15106.D EQUAL SPEARS MANUFACTURING
SSI #49 15106 MODULATING BALL VALVE IW SERVICE
06/13/2014
Page 1 of 148
NAMED MANUFACTURERS - SIZE RANGE DIFFICIENT
NOTE VALVES ARE PREVIOUSLY APPROVED ON 15106-004-A
TFE HAS NO MEMORY AND IS NOT RECOMMENDED FOR BODY SEALS
VITON IS RECOMMENDED AND COMPATABLE WITH ALL SERVICES LISTED
MANUFACTURER SPEARS MANUFACTURING
15852 OLDEN STREET
SYLMAR,CA 91392
818-364-1611
SIZE MODEL NUMBER ENDS
6" 1833-060 FLANGED ENDS
VALVE TAG # PID LOCATION DESCRIPTION AND SERVICE
15LFV742 15L-NP-325 IW SERVICE BALL VALVE WITH ELECTRIC MOTOR OPERATOR -MODULATING
CONTROL ANALOG WITH ANALOG FEEDBACK
15LFV747 15L-NP-325 IW SERVICE BALL VALVE WITH ELECTRIC MOTOR OPERATOR -MODULATING
CONTROL ANALOG WITH ANALOG FEEDBACK
15MFV822 15M-NP-302 IW SERVICE BALL VALVE WITH ELECTRIC MOTOR OPERATOR -MODULATING
CONTROL ANALOG WITH ANALOG FEEDBACK
15MFV827 15M-NP-302 IW SERVICE BALL VALVE WITH ELECTRIC MOTOR OPERATOR -MODULATING
CONTROL ANALOG WITH ANALOG FEEDBACK
ACTUATOR MANUFACTURER FLOWSERVE FLOW CONTROL
LIMITORQUE CORPORATION
5114 Woodall Road
Lynchburg, VA 24506-1318
Phone: 434-528-4400
ACTUATOR MODEL LIMITORQUE QX1-XP-FA10-WD-QX-030110-10000 MODUTRONIC APT 120 REL 1-8
120 VOLT CONTROL WITH HANDWHEEL OVERRIDE
AND INTEGRAL LOCAL CONTROL STATION
CONTROL AT THE ACTUATOR - LOCAL CONTROL PANEL ON THE ACTUATOR IN "LOCAL"
AT THE REMOTE HAND STATION IN "LOCAL"
AT THE ACTUATOR - MANUAL OVERRIDE WITH THE ACTUATOR IN "OFF"
OR NO POWER
DISCRETE CONTROL FROM THE PLC IN "REMOTE"
Special function of monitor relay Output contacts set for “actuator alarm AA” and “Break at valve alarm bA”
VALVE TORQUE REQUIRED 61 FTLBS AT 150 PSI
ACTUATOR RATED TORQUE 100 FTLBS
SAFETY FACTOR >1.5
SPEED RANGE 5-20 SECONDS SET AT 5 SECONDS
TURNS FOR FULL CYCLE 90 DEGREES
POSITION INDICATION VISUAL AND MECHANICAL
VOLTAGE 120/60
SSI #49 15106 MODULATING BALL VALVE IW SERVICE
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FAIL ON LOSS OF POWER LAST POSITION
WIRING DIAGRAMS WD-QX-030110-10000 MODUTRONIC APT 120 REL 1-8 120 CONTROL
ENCLOSURE RATING XP- NEMA 4X; IP68;
DISCONNECT REMOTE MOUNTED WITH EXTRA CONTACT EIM 84550- WITH EXTRA CONTACT
REMOTE HAND STAION NONE
DOCUMENENT SUPPLIED VALVE CATALOG
ACTUATOR CATALOG
VALVE SHOP DRAWINGS
ACTUATOR SHOP DRAWING
INSTRUCTION MANUAL ACTUATOR
INSTRUCTION MANUAL VALVE
VALVE PARTS LIST
ACTUATOR (NO PARTS LIST INCLUDED)
MAINTENANCE INSTRUCTIONS
WARRANTY TWO YEARS FROM DATE OF DATE OF THE FINAL ACCEPTANCE BY THE AGENCY
ASSEMBLY: FACTORY INSTALLED
CYCLE TESTING: MISCOWATER, 27101 BURBANK STE B, FOOTHILL RANCH, CA 92610
FIELD START-UP PERFORMED BY MISCO AS REQUIRED
VALVE IDENTIFICATION STAINLESS STEEL NAMEPLATES ATTACHED TO THE VALVE PER
17075 316 SS TWO HOLE NAMEPLATE WITH SS WIRE
TAG NUMBER
SIZE
TYPE OF VALVE
PID DRAWING
SSI #49 15106 MODULATING BALL VALVE IW SERVICE
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Page 3 of 148
Section 15106
BALL VALVES
PART 1 - GENERAL
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SSI #49 15106 MODULATING BALL VALVE IW SERVICE
06/13/2014
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SPEARS MFR
10
Sample Engineering Specification
All thermoplastic ball valves shall be True Union 2000 Industrial type
manufactured to ASTM F 1970 and constructed from PVC Type I, ASTM
D 1784 Cell Classification 12454 or CPVC Type IV, ASTM D1784 Cell
Classification 23447. All O-rings shall be EPDM or Viton
®
. All valves shall
have Safe-T-Shear
®
stem with double O-ring stem seals. All valve handles
shall be polypropylene with built-in lockout mechanism. All valve union nuts
shall have Buttress threads. All seal carriers shall be Safe-T-Blocked
®
. All
valve components shall be replaceable. All valves shall be certified by NSF
International for use in potable water service. All 1/2" through 2" valves shall
be pressure rated to 235 psi, all 2-1/2" through 6", 8" Venturied and all flanged
valves shall be pressure rated to 150 psi for water at 73° F.
•Chemical & Corrosion Resistant PVC or
CPVC Construction
• Also Available in Spears®LXT™ High Purity,
Low Extractable PVC Material
• Interchangeable with all True Union 2000
Valves Mates with Union 2000 Pipe Unions
• High Impact Polypropylene Handle
• Built-in Handle Lockout
• Schedule 80 Full-Bore Design
• Strong, Buttress Thread Union Nuts
• Spears®Double O-ring Safe-T-Shear®
Stem Design
• EPDM or Viton®O-rings
• Spears®Safe-T-Blocked®Seal Carrier
• Self Adjusting PTFE Floating Seat Design
• Fully Serviceable, Replaceable Components
• Sizes 1/2" - 2" pressure rated to 235 psi @
73°F. Sizes 2-1/2" - 6", 8" Venturied and all
Flanged to 150 psi @ 73°F.
• NSF Certified for Potable Water use
• Suitable for Vacuum Service
• Assembled with Silicone-Free
, Water
Soluble Lubricants
• Manufactured to ASTM F 1970
Optional Vented Ball Valves
Same valve with special ball vent design for
sodium hypochlorite (bleach) and other chemical
applications where entrapped fluids may form
caustic crystalline residues and pressure build up
from gases developed. Valve has a 1/8” vent hole
in ball to equalize internal fluid pressures. Install
valve with ball vent on the pressure (upstream)
side when in closed position.
Optional Accessories*
•
Retro-Fit End Connector Sets for Valve
Replacement
• Split-Nut Repair Kits for Union Nut Replacement
• Supplemental End Connectors
• Round Safety Handles
• Handle Lockout Ring
• Stem Extension Kits
• Square Operator Nuts
• Multi Mount Valve/Actuation
Mounting Kits
TRUE UNION 2000 INDUSTRIAL BALL VALVES
Quick-View Valve Selection Chart
1) For CPVC, add the letter "C" following the size code of part number listed (e.g.,1829-005C, 1821-005CSR)
2) For Special Ball Vent Design, add the letter "V" before the dash separator (e.g.,1829V-005, 1821V-005CSR)
3) 8" Venturied Valves are 6" ball valves fitted with 6x8 end connector adapters.
* See “BALL VALVE ACCESSORIES” section for details of
individual products.
Valve
Size
O-ring
Material
PVC Part Number 1Pressure
Rating
Socket Threaded SR Threaded Flanged Spigot
1/2 EPDM 1829-005 included 1821-005SR 1823-005 1827-005
235 psi
Non-Shock
Water
@ 73° F
(Flanged
150 psi
Non-Shock)
Water
@ 73° F
Viton®1839-005 included 1831-005SR 1833-005 1837-005
3/4 EPDM 1829-007 included 1821-007SR 1823-007 1827-007
Viton®1839-007 included 1831-007SR 1833-007 1837-007
1EPDM 1829-010 included 1821-010SR 1823-010 1827-010
Viton®1839-010 included 1831-010SR 1833-010 1837-010
1-1/4 EPDM 1829-012 included 1821-012SR 1823-012 1827-012
Viton®1839-012 included 1831-012SR 1833-012 1837-012
1-1/2 EPDM 1829-015 included 1821-015SR 1823-015 1827-015
Viton®1839-015 included 1831-015SR 1833-015 1837-015
2EPDM 1829-020 included 1821-020SR 1823-020 1827-020
Viton®1839-020 included 1831-020SR 1833-020 1837-020
2-1/2 EPDM 1822-025 1821-025 1821-025SR 1823-025 1827-025
150 psi
Non-Shock
Water
@ 73° F
Viton®1832-025 1831-025 1831-025SR 1833-025 1837-025
3EPDM 1822-030 1821-030 1821-030SR 1823-030 1827-030
Viton®1832-030 1831-030 1831-030SR 1833-030 1837-030
4EPDM 1822-040 1821-040 1821-040SR 1823-040 1827-040
Viton®1832-040 1831-040 1831-040SR 1833-040 1837-040
6EPDM 1822-060 1821-060 1821-060SR 1823-060 1827-060
Viton®1832-060 1831-060 1831-060SR 1833-060 1837-060
83EPDM 1822-080 — — 1823-080 —
Viton®1832-080 — — 1833-080 —
Features – PVC, CPVC
This multi-featured, space saving quarter-turn shutoff valve is designed to meet the
demands of today's industrial and chemical processing applications. PVC and CPVC
valves are available in IPS sizes 1/2" through 6" with socket/regular thread, SR (Special
Reinforced) thread, flanged or spigot end connectors and 8" Venturied valve with socket or
flanged ends. Also available in metric socket and BSP thread sizes 1/2" through 2".
SSI #49 15106 MODULATING BALL VALVE IW SERVICE
06/13/2014
Page 8 of 148
11
TRUE UNION 2000 INDUSTRIAL BALL VALVES
Replacement Parts
Dimensions, Weights, Operating Torque & CvValues
Temperature Pressure Rating
NOTE: 1) Flanged Valves have a base pressure rating of 150 psi.
No. Component Qty. Material
1 Seal Carrier 1 PVC/CPVC
2 Seat 2 PTFE
3 Body 1 PVC/CPVC
4 Carrier O-ring 1 EPDM/Viton®
5 Stem 1 PVC/CPVC
6 Stem Bearing 1 PP
7 Handle 1 PP
8 Stem O-ring 2 EPDM/Viton®
9 Handle Lock 1 PP
10 Ball 1 PVC/CPVC
11 Union Nut 2 PVC/CPVC
12 End Connector O-ring 2 EPDM/Viton®
13 End Connector 2 PVC/CPVC
System Operating
Temperature °F (°C)
100
(38)
110
(43)
120
(49)
130
(54)
140
(60)
150
(66)
160
(71)
170
(77)
180
(82)
190
(88)
200
(93)
210
(99)
Valve
Pressure
Rating
psi
(Mpa)
1/2” - 2”
PVC 235
(1.62)
211
(1.45)
150
(1.03)
75
(.52)
50
(.34)
-0-
(-0-)
-0-
(-0-)
-0-
(-0-)
-0-
(-0-)
-0-
(-0-)
-0-
(-0-)
-0-
(-0-)
CPVC 235
(1.62)
219
(1.51)
170
(1.17)
145
(1.00)
130
(.90)
110
(.76)
90
(.62)
80
(.55)
70
(.48)
60
(.41)
50
(.34)
-0-
(-0-)
2-1/2” - 8”
PVC 150
(1.03)
135
(.93)
110
(.76)
75
(.52)
50
(.34)
-0-
(-0-)
-0-
(-0-)
-0-
(-0-)
-0-
(-0-)
-0-
(-0-)
-0-
(-0-)
-0-
(-0-)
CPVC 150
(1.03)
140
(.97)
130
(.90)
120
(.83)
110
(.76)
100
(.70)
90
(.62)
80
(.55)
70
(.48)
60
(.41)
50
(.34)
-0-
(-0-)
NOT FOR USE WITH COMPRESSED AIR OR GASES
Nominal
Size
Dimensions Reference (inches, ± 1/16) Approx. Wt. (Lbs.) Oper.2
Torque
(in. lbs.)
Cv3Values
A
B1C
DEFG
PVC CPVC Soc/Thd Flanged Spigot
Soc/Thd Spigot Socket Thread Spigot
1/2 1-7/8 2-3/8 2-7/8 4-3/16 3-3/16 4-5/8 2-9/16 2-13/16 3-1/2 2-31/32 .36 .38 16 29 18 27
3/4 2-1/4 2-3/4 3-1/4 4-3/4 4-1/4 5-1/4 2-7/8 3-3/8 3-7/8 3-5/16 .56 .58 17 63 39 57
1 2-1/2 2-7/8 3-1/2 5-1/8 4-11/16 5-3/4 3-1/8 3-7/16 4-1/2 3-5/8 .74 .77 22 120 73 108
1-1/4 3-1/16 3-1/4 3-13/16 5-3/4 5-3/16 6-5/16 3-5/8 3-7/8 4-5/8 3-31/32 1.13 1.19 28 243 151 223
1-1/2 3-1/2 3-1/2 4 6-1/4 5-7/16 6-3/4 4 4-3/16 5 4-3/8 1.54 1.60 61 357 223 333
2 4-1/4 4-3/4 5-3/16 7-3/4 6-3/4 8-1/4 4-1/2 5-1/8 6 5-1/4 2.72 2.85 77 599 395 571
2-1/2 5-3/8 6-7/8 7-13/16 10-7/16 9-11/16 11-3/8 5-1/8 6-1/4 7-1/2 6 7.42 7.70 132 856 579 734
3 6-3/16 7 7-13/16 10-11/16 9-7/8 11-9/16 5-7/8 7-5/8 7-1/2 6-13/16 7.46 7.81 132 1416 974 1322
4 7-5/8 7-5/16 8-1/4 11-7/8 10-1/4 12-3/4 6-3/4 9-3/16 9 7-1/2 12.35 12.48 396 2865 1952 2672
6 11-5/8 11-1/16 13 17-1/16 15-3/4 18-1/2 8-1/8 14-5/16 11-1/4 10-3/16 37.53 40.55 732 6638 4824 6149
8411-5/8 23-3/16 --- 31-7/8 --- --- 8-1/8 14-5/16 13-1/2 17-13/16 50.84 55.92 732 N/A N/A N/A
1: Valve Lay Length
2: Torque required at valve maximum internal pressure rating, 5ft/sec. Flow velocity; due to adjustment differences during installation, actual valves may vary.
3: Gallons per minute at 1 psi pressure drop. Valves calculated from laying length, based on derivative of Hazen-Williams equation with surface roughness factor of C=150.
4: 8" Venturied Valves are 6" ball valves fitted with 6x8 end connector adapters.
SSI #49 15106 MODULATING BALL VALVE IW SERVICE
06/13/2014
Page 9 of 148
81
GENERAL INSTALLATION
Ease of installation and maintenance is one of the major advantages of using thermoplastic valves. As with any product, certain
procedures must be followed for successful installation, service and long life. This section specifies individual installation and
maintenance service instructions for Spears valves. All applicable instructions and procedures should be read thoroughly
before starting. Suitability of the intended service application should be determined prior to installation. Please review
“Material Considerations in Application and System Design”, in the “MATERIALS” section of this manual for
important additional considerations related to valve installations.
Plastic piping systems should be engineered, installed, operated and maintained in accordance with accepted standards and
procedures for plastic piping systems. It is absolutely necessary that all design, installation, operation and maintenance
personnel be trained in proper handling, installation requirements and precautions for installation and use of plastic piping
systems before starting.
Individual valve installation instructions specific to each product type are packaged with product. The following sections of
this manual contain safety precautions and procedures for making solvent cement, threaded or flanged joints.
Precautions & Warnings for All Valve, Strainer & Accessories Installations
CAUTION: The system shall be designed and
installed so as not to pull the valve in any direction.
Valve and strainers must be supported with
conventional piping system support devices.
Typical Valve Support Example
CAUTION: All valve connectors and connecting pipe
should be inspected for any breaking, chipping, gouging or
other visible damage before proceeding. All joining
components must be clean and dry. All valves and pipe
shall be removed from their packaging or containers and
exposed to the environment for a minimum of one hour in
order to thermally balance all components. Installation
temperatures should be between 40°F and 110°F.
CAUTION: All valves with fixed socket end connectors
in the body must be installed in the open position to aid in
evaporation of solvent vapors which can attack internal
components. WARNING: TAKE EXTRA CARE THAT NO
PRIMER OR SOLVENT CEMENT IS ALLOWED TO
COME IN CONTACT WITH THE BALL OR OTHER
INTERNAL VALVE COMPONENTS.
CAUTION: Threaded pipe connections require
application of a quality grade thread sealant to seal joint
assembly. Sealant should be applied to male pipe threads.
WARNING: SOME PIPE JOINT COMPOUNDS OR
TEFLON®PASTES MAY CONTAIN SUBSTANCES THAT
COULD CAUSE STRESS CRACKING IN
THERMOPLASTIC MATERIALS. Spears Manufacturing
Company recommends the use of Spears BLUE 75TM
thread sealant which has been tested for compatibility with
Spears products. Please follow the sealant manufacturers’
application / installation instructions. Choice of an
appropriate thread sealant other than those listed above is
at the discretion of the installer.
CAUTION: BEFORE THE VALVE IS CYCLED, all
dirt, sand, grit or other material shall be flushed from the
system. This is to prevent scarring of internal
components; e.g., ball, cup, wedge, seats, etc.
WARNING: Some Lubricants, including
vegetable oils, are known to cause stress cracking
in thermoplastic materials. Commercially available
pipe gasket lubricants suitable for PVC and CPVC
should be used where lubrication is needed for
installation or maintenance service (Seacord Ease-On
or equivalent). These water-soluble lubricants can be
mixed with water where "a mild soap and water
solution" is specified to be used. Choice of lubricant is
at the discretion of the installer.
WARNING: DO NOT USE COMPRESSED AIR OR
GAS TO TEST ANY PVC OR CPVC THERMOPLASTIC
PIPING PRODUCT OR SYSTEM, AND DO NOT USE
DEVICES PROPELLED BY COMPRESSED AIR OR GAS
TO CLEAR SYSTEMS. THESE PRACTICES MAY
RESULTIN EXPLOSIVE FRAGMENTATION OF
SYSTEM PIPING AND COMPONENTS CAUSING
SERIOUS OR FATAL BODILYINJURY. All air must be
bled from the system during initial fluid fill. Pressure testing
of the system should not be made until all solvent cement
joints have properly cured. Initial pressure testing should be
made at approximately 10% of the system hydrostatic
pressure rating to identify potential problems, prior to testing
at higher pressures.
WARNING: Systems should not be operated or flushed
out at flow velocities greater than 5 feet per second.
SSI #49 15106 MODULATING BALL VALVE IW SERVICE
06/13/2014
Page 10 of 148
Section 15101
VALVE OPERATORS
PART 1 - GENERAL
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06/13/2014
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PLASTIC VALVE VOLTAGE IS 120/60
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, Configuration/Programming Submittal
All equipment, devices and/or instruments that requires configuration or
programming. The submitted program shall be in native format and shall be
provided with the associated relevant software. For record purposes each
individual file shall be saved separately with filename as tag number in the
native format and submitted.
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