Hydra-Stop 4-8 Insta-Valve 250 Patriot Series

Transcription

1 Hydra-Stop 4-8 Insta-Valve 250 Patriot Series Insertion Valve Specification IV_250_PAT_4-8_SPECS v1.2 Revised July 2015

2 Hydra-Stop 4-8 Insta-Valve 250 Patriot Series Insertion Valve Specification All Insertion Valves shall conform to the following: Insertion valve shall be an all stainless steel body Resilient Wedge Gate Valve designed for permanent use in potable water, sewage, raw water, reclaimed water, irrigation and backflow control systems. The design will allow the valve to be installed into an existing pressurized pipeline while maintaining constant pressure and service without system shutdown. No restraining devices, restraining fasteners, or transition gaskets shall be required for the installation or operation of the valve. Installation Method: Traditional line tapping methods shall be used for the Installation of all Insertion Valves to allow removal of a single coupon for system evaluation. Reaming the pipe, complete removal of a section of pipe (top & bottom), or milling a slot in the pipe shall be prohibited. Trained & Authorized Installer: All Insertion Valves must be installed by companies trained and authorized by the approved valve manufacturer. This will ensure high quality installation and guarantee the warranty of the product. Valve Body and Bonnet Construction: All insertion valves shall have a stainless steel body, bonnet and a reinforced composite polymer valve cartridge to provide superior corrosion resistance, strength and a pressure rating that meets or exceeds the requirements of resilient seated gate valves. The insertion valve shall be stainless steel construction for corrosion resistance, maximum toughness and strength. All insertion valves must be capable of working on Cast/Grey Iron or Ductile Iron Class A, B, C and D, IPS PVC, C900 and C909 PVC, Steel and AC pipe diameters without changing either top or bottom portion of split valve body or using a transition gasket. All insertion valves must provide a solid support of the host pipe through the entire laying length of the valve body. No gaps or space between the valve body and host pipe shall be accepted. All insertion valves shall be rated for 250 psig maximum working pressure. The pressure rating must be permanently marked into the body. All insertion valves must be hydrostatically pressure tested to 1.25 times of the system operating pressure (minimum) or 1.5 times of the Insertion Valves 250 psig maximum pressure rating. The test shall be sustained for a minimum of 15 minutes. Once the pressure test is affectively achieved the insertion valve body must not be moved in accordance with AWWA Standards. If the insertion valve body is moved the pressure test must be completed again. Any movement, repositioning, loosening and/or retightening must be retested before the pipe is tapped. 144 Tower Drive, Burr Ridge, IL

3 Resilient Wedge Gate Assembly: Insertion valves shall have an EPDM molded resilient wedge seal. The resilient wedge seal will be affixed into a re-inforced nylon composite polymer valve cartridge. The entire assembly shall be inert and impervious to corrosion. The nylon composite polymer valve cartridge shall be engineered to come into contact with the interior of the host pipe and an engineered sealing surface in the valve body to create a seal. The resilient wedge shall be reinforced to resist abrasion thus extending the life and quality of the shutdown where the wedge contacts the host pipe. Pressure equalization on the down or upstream side of the closed wedge shall not be necessary to open the valve. The wedge shall be symmetrical and seal equally well with fl ow in either direction. The Resilient wedge must ride inside a minimum of four body channels to maintain wedge alignment throughout its travel and to achieve maximum fl uid control regardless of high or low fl ow pressure or velocity. Insertion valves shall have a full size, full port fl ow way that is unobstructed, and free of depressions to provide optimum fl ow and sealing and not trap tuberculation or debris. Valve Dimensions and Weight: Maximum height of the valve from the center of the host pipe to the top of the operating nut shall not exceed the following dimensions: o 4 = 18.6 o 6 = 21.5 o 8 = 24.6 Maximum laying length of the valve body shall exceed the following dimensions: o 4 = 12 o 6 = 12 o 8 = 16 Maximum weight of the valve shall not exceed the following weight: o 4 = 138 lbs. o 6 = 173 lbs. o 8 = 229 lbs. Fusion-Bonded Epoxy / E Coating: Insertion valves shall have all stainless steel bodies and fasteners. The use of epoxy coatings for protection against corrosion is deemed insufficient. 144 Tower Drive, Burr Ridge, IL

4 Gaskets and Stem Seals: Insertion valves shall utilize four O-Ring s to seal between valve body to valve bonnet and valve stem. These O-rings shall be located in such a fashion as to ensure the 250 psig pressure worthiness and prevent ground water and/or foreign materials from entering the valve. Valve Stem: Insertion valves shall be NRS (non- rising stem) and operate with standard turns 3 turns per diameter inch to open and close. Insertion valves shall be operated by a 2 square wrench nut open left or open right. The gate valve stem shall be made of stainless steel. The gate valve stem shall be able to withstand torque of 700 ft. lbs. of torque without compromising operation. The NRS stem must have an integral stem collar manufactured of no lead bronze. Two-piece stem collars are not acceptable. The stem shall be affixed into the valve cartridge to maintain stem alignment, low torque and continuous operation of the valve. Hardware: All Bonnet and valve body fastener hardware shall be stainless steel and must meet Made in the USA requirements. Valve cartridge locking pins shall be made of grade 8 zinc coated carbon steel to prevent galling with stainless steel pin plugs coated to prevent galling. Both must meet Made in the USA requirements. Split Restraint Devices & Fasteners: Insertion valves that require the use of external or integral split restraint devices and or restraint fasteners is prohibited. Quality Assurance: Insertion valves shall be factory pressure tested and serialized for traceability before leaving the manufacturing facility to assure quality. Proof of successful factory pressure test must be made available upon customer request in three business days. Made in the USA: All components shall be made in the USA. And meet the Made in the USA, American Iron and Steel, and Buy America legislation. 144 Tower Drive, Burr Ridge, IL

5 Value Added Features and Benefits: All moving and operating parts must be removable, repairable and or replaceable under pressure to ensure easy repair of broken or damaged parts. Insertion valves must have the ability to be converted to a line stop fitting in the field without modification. The 4-8 Insertion Valve shall be a Hydra-Stop Insta-Valve 250 Patriot Series (Patents Pending) or written preapproved equal. APPROVED BY: Name: Title: Date: / / 144 Tower Drive, Burr Ridge, IL

6 ADDENDUM: CUT SHEET IV 250 Patriot Series Valve Insertion System - 4, 6, 8 inch Nominal Sizes Product Cut Sheet - IV 250 IV 250 ASSEMBLY ITEM DESCRIPTION MATERIAL QTY 1 NUTS (BONNET, MOUNTING AND OPERATING NUT ATTACHING NUT) 304 STAINLESS STEEL* SEE NOTE 2 OPERATING NUT STEEL, CAST 1 3 BONNET BOLTS 304 STAINLESS STEEL 8 4 BONNET 304 STAINLESS STEEL 1 5 THRUST WASHER TEFLON 1 6 VALVE STEM 304 STAINLESS STEEL 1 7 COMPLETION PLUG REINFORCED COMPOSITE POLYMER 1 8 COMPLETION PLUG O-RING RUBBER, BUNA-N 1 9 VALVE STEM O-RING RUBBER, BUNA-N FLANGE O-RING RUBBER, BUNA-N 1 11 PIN PLUGS 304 STAINLESS STEEL 4 12 COMPLETION PLUG PINS 13 WASHERS BONNET AND BODY MOUNT WASHERS ** SAE GRADE 8 STEEL, ZINC COATED 304 STAINLESS STEEL 4 SEE NOTE 14 IV 250 PATRIOT SERIES BODY 304 STAINLESS STEEL 1 15 VALVE PIN STEEL, MILD 4 16 STEM COLLAR NO LEAD BRASS 1 17 IV 250 CARTRIDGE REINFORCED COMPOSITE POLYMER 1 18 CARTRIDGE SEAL EPDM 1 19 WEDGE BOLT STAINLESS STEEL BODY MOUNT CARRIAGE BOLTS 304 STAINLESS STEEL 8 21 MOUNTING BODY - TOP 304 STAINLESS STEEL 1 22 WEDGE BOLT STAINLESS STEEL RESILIENT WEDGE EPDM 1 24 MOUNTING BODY - BOTTOM 304 STAINLESS STEEL 1 25 BODY SEALING GASKET RUBBER, BUNA-N 1 26 BOTTOM BODY SEALING GASKET*** RUBBER, BUNA-N 1 * Coated to prevent galling. ** 4 and 6 valve requires 1 operating nut attaching nut, 8 bonnet nuts and bolts and 16 bonnet washers, 8 mounting bolts, nuts and washers. 8 valve requires 1 operating nut attaching nut, 8 bonnet nuts and bolts and 16 bonnet washers, 10 mounting bolts, nuts and washers. *** 8 valve only Weights and Dims Size A B C D Approx. Weight lbs lbs lbs Other Specifications Minimum Test Pressure: 1.5 times system working pressure Maximum Test Pressure: 375 psi Maximum Working Pressure: 250 psi Proprietary Information: This property of Hydra-Stop shall not be used, reproduced or distributed without written consent. All design and invention rights are reserved. Patents Pending. 144 Tower Drive Burr Ridge, IL Specifications subject to change without notice. CS-IV250PS

7 ADDENDUM: GENERAL SPECIFICATIONS IV 250 Patriot Series Valve Insertion System - 4, 6, 8 inch Nominal Sizes Material Specifications: Body Armor Shields: 16 gauge 304 Stainless Steel. Body Mounting Bolts: 304 Stainless Steel. 5/8-11 UNC6. Body Sealing Gasket: BUNA-N Rubber. Body: 304 Stainless Steel. Bonnet and Body Mounting nuts: 304 Stainless Steel. Nuts coated to prevent galling. Bonnet Bolts: 304 Stainless Steel. 5/8 UNC rolled thread. Bonnet: 304 Stainless Steel. Cartridge Seal: EPDM Completion Pin Plugs: 304 Stainless Steel. Coated to prevent galling. Completion Plug O-ring: BUNA-N Rubber. Completion Plug Pins: SAE Grade 8. Zinc coated to prevent corrosion. Completion Plug: Reinforced Composite Polymer Flange O-Ring: BUNA-N Rubber. Flange: 304 Stainless Steel. IV 250 Valve Cartridge: Reinforced Composite Polymer. Mounting Body Bottom: 14 gauge 304 Stainless Steel. Mounting Body Top: 11 gauge 304 Stainless Steel. Mounting Lugs: 304 Stainless Steel. Operating Nut: Steel, Cast. Resilient Wedge: Reinforced EPDM. Stem Collar: No Lead Brass. Valve Body: 304 Stainless Steel Valve Stem: 304 Stainless Steel. Washers: 5/8 304 Stainless Steel. Design Specifications: Factory Pressure Test: Each IV 250 Patriot Series Valve is pressure tested and serialized for traceability before leaving our manufacturing facility. Integrated Lifting Gussets: Incorporated to facilitate safe handling. IV 250 Test and Working Pressures: 250 psi working pressure. 375 psi test pressure max. Welds: Welds fully passivated for improved corrosion resistance. The IV 250 Patriot Series Insertion Valve is manufactured in the USA with 100% domestic materials. Meets Made in USA and American Iron and Steel Requirement (Public Law ). Fulfills requirements specified in additional Buy America legislation. 144 Tower Drive Burr Ridge, IL Specifications subject to change without notice. SPEC-IV250PS

8 IV 250 Valve Insertion System - 4, 6, 8 inch Nominal Sizes Product Cut Sheet - IV 250 IV 250 ASSEMBLY ITEM DESCRIPTION MATERIAL QTY 1 NUTS (BONNET, MOUNTING AND OPERATING NUT ATTACHING NUT) 304 STAINLESS STEEL* SEE NOTE 2 OPERATING NUT STEEL, CAST 1 3 BONNET BOLTS 304 STAINLESS STEEL 8 4 BONNET EPOXY COATED CARBON STEEL 1 5 VALVE STEM 304 STAINLESS STEEL 1 6 COMPLETION PLUG REINFORCED COMPOSITE POLYMER 1 7 COMPLETION PLUG O-RING RUBBER, BUNA-N 1 8 VALVE STEM O-RING RUBBER, BUNA-N 1 9 FLANGE O-RING RUBBER, BUNA-N 1 10 PIN PLUGS 304 STAINLESS STEEL 4 11 COMPLETION PLUG PINS 12 WASHERS BONNET AND BODY MOUNT WASHERS ** SAE GRADE 8 STEEL, ZINC COATED 304 STAINLESS STEEL 4 SEE NOTE 13 IV 250 BODY 304 STAINLESS STEEL 1 14 VALVE PIN STEEL, MILD 4 15 STEM COLLAR NO LEAD BRASS 1 16 IV 250 CARTRIDGE REINFORCED COMPOSITE POLYMER 1 17 CARTRIDGE SEAL EPDM 1 18 WEDGE BOLT STAINLESS STEEL BODY MOUNT CARRIAGE BOLTS 304 STAINLESS STEEL 8 20 MOUNTING BODY - TOP 304 STAINLESS STEEL 1 21 WEDGE BOLT STAINLESS STEEL RESILIENT WEDGE EPDM 1 23 MOUNTING BODY - BOTTOM 304 STAINLESS STEEL 1 24 BODY SEALING GASKET RUBBER, BUNA-N 1 25 BOTTOM BODY SEALING GASKET*** RUBBER, BUNA-N 1 * Coated to prevent galling. ** 4 and 6 valve requires 1 operating nut attaching nut, 8 bonnet nuts and bolts and 16 bonnet washers, 8 mounting bolts, nuts and washers. 8 valve requires 1 operating nut attaching nut, 8 bonnet nuts and bolts and 16 bonnet washers, 10 mounting bolts, nuts and washers. *** 8 valve only Weights and Dims Size A B C D Approx. Weight lbs lbs lbs Other Specifications Minimum Test Pressure: 1.5 times system working pressure Maximum Test Pressure: 375 psi Maximum Working Pressure: 250 psi Proprietary Information: This property of Hydra-Stop shall not be used, reproduced or distributed without written consent. All design and invention rights are reserved. Patents Pending. 144 Tower Drive Burr Ridge, IL Specifications subject to change without notice. CS-IV250PS

9 Insta-Valve Plus Valve Insertion System 10 and 12 inch Nominal Sizes IVP416SPECS v1.2 Revised March, 2014

10 Insta-Valve Plus Valve Insertion System - 10 and 12 inch Nominal Sizes SCOPE: The Insta-Valve Plus System shall provide a means to install a permanent block (open-close) valve into a pressurized pipe - with no interruption of fl ow through the pipe and no reduction of line pressure. The insertion of an Insta-Valve Plus shall be accomplished through a single circular hole cut (under full line pressure) into the top of the pipe. The Insta-Valve Plus, itself, permanently remains in the piping to allow shutdowns in the same manner as any gate, ball or butterfl y block valve. 1. Machinery and Equipment This specifi cation covers the furnishing, complete of one (1) new Insta-Valve Plus System with choice of air or hydraulic drive motor. 1.1 Equipment Capability The equipment shall be capable of the installation, without shutdown, of a valve insertion, in the range of ten (10) inch diameter through twelve (12) inch diameter. Method of pipe entry shall be made using a carbide tipped cutter and a pilot drill with retaining wire to retain the coupon. Reaming or milling of the pipe shall not be acceptable. This equipment shall be rated for line pressures up to 150 psi and have the following capabilities: Allow installation of open left (clockwise close) and open right (anti-clockwise close). Installation shall not disturb existing utilities in close proximity to the valve location. Expansion to single and double sets of line stopping equipment in sizes 4-20 without factory rework. Expansion to line stopping to be rated to line pressures up to 150 psi or 250 psi. Expansion to side tapping 3-20 with optional adapter kits. Expansion to valve insertion 16 with additional adapter kit. The capabilities specifi ed herein are minimum mandatory requirements that must be met by any equipment offered. Equipment shall be manufactured by Hydra-Stop. No substitutions will be allowed. Insta-Valve Plus Equipment (10-12 ) (Manufacturer Part# 3-412IV-412) Quantity Description 1 each Tapping (drilling) Machine: (4-12 ) 1 each Drive Motor: Hydraulic 1 each Shell Cutter: Carbide tooth: (10 & 12 ) (2 total) 1 each Pilot Drill: (10 & 12 ) (2 total) 1 each Saw Mandrel: (10 12 ) (1 total) 1 each Temporary Valve (10-12 ) (1 total) 1 each 1 3/8 Bronze Top and 30 Feed Screw 1 each Housing: (10 12 ) (1 total) 1 each Insertion Housing: (10-12) (1 total) 1 each Insertion Tool: (10-12 ) (1 total) 1 each Guide Plate 1 each Blind Flange with test port: (12 ) (1 total) 1.2 Equipment: Note: Side tapping expansion kit is required for branch connections S. Cicero Avenue Alsip, IL

11 Insta-Valve Plus Valve Insertion System - 10 and 12 inch Nominal Sizes The size and weights of each (10-12 ) Insta-Valve Plus Unit shall be such that two (2) workmen can assemble the machinery and manually transport it over a fairly level construction site without the use of hoisting equipment. Once lowered into an excavation, two (2) workmen can mount the machinery onto the Insta-Valve fi tting without further hoisting assistance. All requirements expressed as mandatory in this paragraph and all requirements expressed as mandatory in all of the subparagraphs of this section, i.e., as requirements that shall be met, are minimum mandatory requirements that must be met by any equipment offered. 1.3 Delivery: Delivery is required within 30 days after receipt of purchase order. Failure to meet this delivery date may be deemed as non-responsive. Freight allowed. 1.4 Warranty: The manufacturer shall supply a one year warranty on defective materials. Cutters & pilot drills shall be excluded from this warranty. 1.5 Training: A qualifi ed representative of the manufacturer shall provide eight (8) hours of demonstration and training in the use of the equipment specifi ed. All cost for this training will be included in the prices bid for the equipment. 2. Insta-Valve Plus: The Insta-Valve Plus shall consist of three subassemblies: the Valve Body, which shall be mounted pressuretight around the main; the Valve Cartridge, which shall be inserted, under full line pressure, into the Valve Body; and the Cartridge Closure Flange, which shall secure and permanently seal the Cartridge to the Body. Test and maximum operating pressures prior to tapping shall be as follows: Test pressure: 225 psi Working pressure: 150 psi A. Valve Body: The Valve Body shall consist of a two-part stainless steel fitting of the Saddle type with a Type 304L stainless steel hollow cylindrical nozzle, welded to the upper saddle half. The two part Body shall be assembled around the pipe and pressure-sealed to the main by a single griddled resilient sheet gasket and throat gasket. The gasket shall fully encircle the pipe, providing a 360-deg. full area seal. Suitable fasteners and supporting lugs shall be provided, as specifi ed below. (1) Saddles: Saddles shall be formed from Type 304L stainless steel. The design of the Saddles, Bolting, Lugs and Armor Plates shall be such that the Fitting halves can be mounted, without further modifi cation, pressure-tight onto the following 10 and 12 nominal size pipes: 1) Cast Iron: Pit Cast - Classes A, B, C. & D 2) Cast Iron: Centrifugal - Classes all 3) Asbestos-Cement: Classes 100, 150 & 200 4) Ductile Iron: Classes all S. Cicero Avenue Alsip, IL

12 Insta-Valve Plus Valve Insertion System - 10 and 12 inch Nominal Sizes 5) PVC (AWWA C900): Classes 100, 150, & 200 (2) Bolting Lugs Bolting lugs shall be Type 304L stainless steel weldments and shall be designed and positioned on the fi tting halves to insure accurate assembly of both halves. After assembly around the pipe, the vertical spacing of the Bolting Lugs between the two fi tting halves shall allow adjustment to accommodate the range of pipe diameters specifi ed above. (3) Bolting Studs: Bolting Studs, Nuts, along with any formed metal washers shall be fabricated from Type 304 stainless steel. All screw threads shall be 5/8-11UNC-2 (coarse). Nuts shall be heavy series. The number of fasteners per side of each fi tting shall be as follows - 10 :6; 12 : 6. (4) Sheet Gasket: Sheet Gasket shall be molded from a virgin SBR elastomer compound that will resist compression set and is compatible with cold drinking water in the normal 32 to 120 deg. A griddled ( waffl e ) pattern shall be molded on the inner side of the gasket. Each side (which lies parallel to the run of the pipe) of the Gasket shall be tapered to allow uniform distribution of clamping (gasket) pressure over the entire circumference of the pipe. A stainless steel Armor Plate shall be attached to each side of the Gasket to bridge the gap between the Saddle Halves. (5) Nozzle Nozzle of the Upper Fitting Half shall be machined from Type 304 stainless steel, and shall have a weldneck Valve Flange with locking pins to mate with the top groove of the Stuffi ng Box Plate (which is part of the Valve Cartridge). Below these locking pins, the interior of the Nozzle shall be accurately bored to seal against the O - ring contained in the Stuffi ng Box Plate. The bore shall be further machined to provide a shoulder to vertically locate the Valve Cartridge when it is inserted into the Body. 1) Two opposing rectangular keyways shall be machined into the interior wall of the Nozzle to receive the Guide Keys on the Valve Cartridge Carrier. B. Valve Cartridge: Valve Cartridge shall consist of a Stuffi ng Box Plate, Valve Stem with Operating Nut, Valve Plugging Head that shall consist of a Carrier with an internal Deformable Sealing Element and two external Resilient Sealing Sleeves, and ancillary parts and fasteners. This Cartridge shall be inserted into the Nozzle under full line pressure by means of a Cartridge Inserter, which shall be attached to the Drilling Machine (that cut the access hole into the top of the main). (1) Stuffing Box Plate: Stuffi ng Box Plate shall retain the collar of the Valve Stem against the Cartridge Closure Flange to prevent vertical motion during normal operation of the Insta-Valve Plus. Suitable thrust washers shall be installed above and below the Stem collar. 1) The bore of this plate shall provide a pressure sealing surface for 0 -rings mounted on the valve stem. 2) The exterior of this plate shall be grooved to receive locking pins installed from the nozzle fl ange after plate has been inserted into the nozzle and has seated against the internal nozzle shoulder. Below this pin groove, the plate shall be further machined to accept a 0 -ring to provide a pressure-seal between the exterior of the plate and the bore of the nozzle S. Cicero Avenue Alsip, IL

13 Insta-Valve Plus Valve Insertion System - 10 and 12 inch Nominal Sizes (2) Valve Stem: During normal operation of the Insta-Valve Plus, rotation of the stem shall advance the valve carrier with sealing devices into the fully closed position to stop fl ow in the pipe. Reversal of stem rotation shall retract the carrier into the completely open position, allowing full fl ow through the main.the stem shall be machined from stainless steel with a 700 LB torque capacity. 1) At customer s option, the stem shall be machined to open the valve by turning it clockwise (open right) or counter clockwise (open left). 2) The top the stem shall be provided with a detachable, 2 square operating nut. 3) Valve shall be operated at 3 turns per inch for 10 and 12. (3) Valve Plugging Head: Valve plugging head shall consist of two major components: rigid cylindrical Carrier and three elastomer sealing devices, along with connecting parts and fasteners. 1) Carrier shall be a rigid, solid cylinder, turned to provide clearance to enter the access (tapped) hole in the pipe. A vertical central slot shall be machined into the lower portion of the Carrier. This slot shall contain a single fl at Deformable Sealing Element. The Carrier shall consist of a solid CM-909 body with rubber coating on the middle half of the CM-909 body. 2) Bottom of Carrier shall be hemispherical to generally conform to the bore of the pipe. It shall be designed to break and to dislodge tuberculation and other deposits that might interfere with a suitable shutdown. 3) The Carrier top, above the slot, shall contain an internal stainless steel thread to mate with that on the Valve Stem. Suitable mechanical means shall be provided to attach the Deformable Element to the Carrier to insure retraction upon opening. 4) Rectangular Guide Keys shall be inserted to the top of the Carrier. These Keys shall be positioned to engage with and slide in the keyways machined into the interior walls of the Nozzle. This action shall maintain alignment of the Valve Cartridge when the Insta-Valve Plus is operated. 5) A single Deformable Sealing Element shall be contained inside the slot in the Carrier. The Element shape shall be generally fl at with the lower end semi- circular to seal the bottom of the pipe. The Carrier shall deform that Element into sealing contact with the pipe wall when the Insta-Valve Plus is closed. 6) A Resilient Sleeve shall be attached to each of the two vertical cylindrical sides of the Carrier. When the Insta-Valve Plus is closed, these two Sleeves shall seal against the Deformable Element and those surfaces of the pipe not sealed by the element, thereby completing the shutdown. C. Cartridge Closure Flange: The Cartridge Closure Flange with a fl at fl ange gasket shall be used to complete the installation of the Insta- Valve Plus. After the Stuffi ng Box Plate has been seated on the shoulder in the Nozzle and the Lock Screws have been tightened from the Nozzle Flange, the Valve cartridge is now mechanically secure in the Valve Body. All water leakage paths have been sealed. The installation equipment shall now be removed and the Closure Flange shall be installed over the thrust washer in the Valve Stem. A Stem O - ring shall pressure-seal against a bored hole in the Closure Flange. The Flange shall then be bolted to the Nozzle fl ange, followed by installation of the Valve Operating Nut. (1) Materials 1) Cartridge Closure Flange, at manufacturer s option, shall be machined from mild structural steel, cast or ductile iron S. Cicero Avenue Alsip, IL

14 Insta-Valve Plus Valve Insertion System - 10 and 12 inch Nominal Sizes D. Pressure: The Insta-Valve Plus does not guarantee a 100% shutdown due to unknown factors within the pipe. The Insta- Valve Plus is rated to 150 PSI working pressure and 225 PSI test pressure. APPROVED BY: Name: Title: Date: / / S. Cicero Avenue Alsip, IL

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16 IVP inch Specifications IVP412SPECS v1.1 Revised August 2013

17 IVP 250 Valve Insertion System - 16 inch Nominal Size The 16 IVP 250 from Hydra-Stop is an insertable gate valve that is design to be installed onto a working, pressurized pipe to provide a control point in a piping system the same day. Like the Insta-Valve Plus product line offered by Hydra-Stop, the IVP 250 installs in three basic steps: 1. Mount the valve body onto the host pipe; 2. Hot Tap the host pipe; 3. Insert the valve cartridge into the valve body. This procedure is able contain the pipe pressure though out the entire process through the use of a temporary knife gate valve that installs onto the flange of the IVP valve body. ITEM DESCRIPTION MATERIAL 1 VALVE BODY CLAMP STAINLESS STEEL 2 VALVE BODY BRANCH STAINLESS STEEL 3 VALVE BODY FLANGE STEEL (PAINTED) 4 GATE* CAST NYLON 5 GATE HOUSING CAST NYLON 6 VALVE STEM** STAINLESS STEEL 7 STEM NUT ALUMINUM BRONZE 8 GATE SEALS EPDM 9 PADDLE SHIELD ALUMINUM (ANODIZED) 10 VALVE BODY GASKET BUNA-N 11 THRUST WASHERS (2) ACETAL 12 RETENTION PLATE ALUMINUM 13 COMPLETION PLUG ALUMINUM 14 TOP FLANGE*** CARBON STEEL (EPOXY COATED) 15 FLANGE NUTS AND BOLTS STAINLESS STEEL 16 VALVE BODY NUTS, BOLTS, AND WASHERS STAINLESS STEEL 17 OPERATING NUT**** DUCTILE IRON (PAINTED) 18 PINS (8) STEEL (ZINC PLATED)/ BUNA-N 19 PLUGS (8) STEEL (PAINTED) 20 GATE HOUSING O-RINGS (2) BUNA-N * CONTAINS STAINLESS STEEL HARDWARE ** SEALS: TWO BUNA-N O-RINGS *** SEALS: BUNA-N X-RING AND BUNA-N/URETHANE LIP SEAL **** SECURED TO VALVE STEM WITH STAINLESS STEEL NUT AND ZINC PLATED STEEL LOCK WASHER 144 Tower Drive, Suite A Burr Ridge, IL

18 IVP 250 Valve Insertion System - 16 inch Nominal Size General Specifications*: For use on inches inside diameter Ductile Iron, PVC pipe or AC pipe. Please consult Hydra-Stop for proper shell cutter, valve cartridge and valve body combinations. Allows for Bi-Directional Flow Installation results in an Unobstructed Waterway Non-Rising Stem available in the open left and open right directions IVP-250 Weight = 865 lbs o Valve Cartridge = 245 lbs o Valve Body = 620 lbs * Contact Hydra-Stop for custom applications Performance Specifications: Maximum Working Pressure: 250 psid Maximum Test Pressure: 375 psid for the IVP-250 Operating Temperature: 33º - 125º F Leakage: 0 GPM o Note: Leakage is dependent on the condition of the pipe and a proper installation and a small amount of bypass (<1 GPM) may result depending on these factors Number of Turns to Close: o The number of turns is dependent on the amount of gate seal rubber compression and expansion required to seal on the inside diameter of the host pipe; pipes with larger inside diameters will be on the high end of the range Operating Torque for Closing: ft-lbs Typical o The operating torque to close is dependent on the amount of gate seal rubber compression and expansion required to seal on the inside diameter of the host pipe; pipes with larger inside diameters will be on the high end of the range Operating Torque for Opening: ft-lbs Typical The operating torque to open is dependent on the pressure differential across the closed gate at the start of opening, where a full 250 psid pressure differential will require the most torque to bring the gate off its seat. As the gate opens and pressure is relieved, the torque will reduce significantly. 144 Tower Drive, Suite A Burr Ridge, IL

19 IVP 250 Valve Insertion System - 16 inch Nominal Size Components: Valve Body: The valve body houses the internal components of the valve and clamps onto the host pipe. The valve body is made of three subcomponents; the valve clamp, branch and flange welded together. Each of these subcomponents is described in detail below. Valve Body Clamp: The valve body clamp is the bottom portion of the valve body that secures the valve to the host pipe. The clamp is made of a top and bottom section that are shaped to fit onto the host pipe. Along the sides of the two sections are lug bars that receive the threaded studs or bolts and provide the surfaces that support the nuts than are tightened onto the threaded studs or bolts, which results in the top and bottom sections of the clamp to be pulled toward one another and squeeze the host pipe. This mounting process creates the foundation for the valve. The valve body clamp is made of 304 Stainless Steel with a passivated finish. The following components are included in the valve body clamp assembly: Gasket The gasket is glued into a circular groove on the inside of the top portion of the clamp and creates a seal between the valve body and host pipe to contain pressure after the pipe is tapped. The two rubber seals extending from the gasket to the inside diameter fo the valve body branch from a seal with the gate when that valve is closed and between the host pipe and clamp. The gasket is made of Buna-N and SBR. Hardware The hardware used to mount the clamp onto the pipe includes threaded studs (14) for the IVP-250 or bolts (14) for the IVP-150, washers (56), and nuts (28). All hardware is made of 304 Stainless Steel. Valve Body Branch: The valve body branch is the cylindrical portion of the valve body that extends for the clamp. The valve body branch contains, in addition to the valve body flange, houses the valve cartridge. The vale body branch is made of 304 Stainless Steel with a passivated finish. Valve Body Flange: The valve body flange provides a bolt pattern on the top of the valve that is used to install the temporary knife gate valve during installation and fasten the top flange for final assembly. The valve body flange also provides the means of securing the valve cartridge, making a pressurized installation possible, through eight ports along the outside diameter of the flange that the receive pins that hold the valve cartridge. The valve body flange is made from carbon steel and is painted for rust protection. The following components are included in the valve body flange assembly: Pins Eight pins thread into the ports on the outside diameter of the valve body flange and are threaded deeper into the flange during the valve insertion process to enter slots in the valve cartridge s completion plug. The pins are made of high strength 1144 Steel to hold the valve cartridge against the upward thrust from the pressurized pipe and are zinc plated for corrosion resistance. Each pin exhibits a Buna-N o-ring to minimize the water that discharges from the port during the valve insertion process. 144 Tower Drive, Suite A Burr Ridge, IL

20 IVP 250 Valve Insertion System - 16 inch Nominal Size Plugs Each pin of the eight pins is backed up by a plug that threads into the start of each port. The plugs are required to seal off each port during pressure testing of the valve body and provide backup seals for the valve cartridge. The plugs are made of steel and are painted for rust protection O-Ring The face of the valve body flange contains a o-ring groove that contains a Buna-N o-ring that forms a seal between the valve body flange and top flange. This seal provides back up for the valve cartridge seals. Gate: The gate valve component that travels down into and seals upon the host pipe to isolate pressure and stop flow. The gate is made from Food Grade Cast Nylon, Type 6 for its light weight and low friction characteristics. The gate assembly contains a variety of components that enable the travel of the gate and allow the gate to seal onto the pipe. The following components are included in the valve stem assembly: Gate Seals the gate utilizes two gate seals, both made of EPDM rubber, to form a seal on the host pipe. The top gate seal wraps around the gate and forms a seal on the gate housing and the inside of the valve body. The bottom gate seal forms a seal primarily inside of the host pipe and inside of the valve body as well. Continued closing of the gate after the bottom seal makes contact with the host pipe results in compression and expansion of the gate seal that forms a complete seal on the inside diameter of the host pipe. Paddle Shields (2) On each side of the bottom gate seal, or paddle, is a paddle shield that supports the rubber seal against severe flow conditions. The paddle shields are made of aluminum and are hard coat anodized. Retention Plate The retention plate is made from high strength 7075 Aluminum and bolts into the top of the gate to retain the stem nut. Gate Hardware A variety of hardware is contained within the gate to hold the retention plate, bottom gate seal, and paddle shields in place. All hardware is made of Stainless Steel. Gate Housing: The gate housing is the valve component that directs the gate travel into the host pipe. When the valve stem of the valve is rotated, the gate housing prevents the rotation of the gate, which results in gate travel in the direction of the valve stem. In addition to enabling gate travel, the gate housing is critical for valve sealing and installation as it makes up the bulk of the valve cartridge. The gate housing is made from Food Grade Cast Nylon, Type 6 for its light weight and low friction characteristics. The following components are included in the valve stem assembly: Completion Plug The completion plug is secured to the top of the nylon gate housing to provide a stronger material, aluminum, to support the upward thrust on the valve cartridge caused by pressure within the host pipe. The completion plug is loaded by the upward thrust at the eight slots along the outside diam- 144 Tower Drive, Suite A Burr Ridge, IL

21 IVP 250 Valve Insertion System - 16 inch Nominal Size eter that each receive a pin that is threaded into the valve body flange. The higher strength of the aluminum in comparison to nylon is critical again to support the valve stem during the opening of the valve as the shaft collar of the valve stem rotates within the completion plug. O-Rings (2) The gate housing contains an o-ring at the top of the assembly that forms a seal inside of the valve body flange and second o-ring, in two separate sections, that forms a seal on the inside of the valve body branch as well as the gate seal. Both o-rings are made of Buna-N Valve Stem: The valve stem is part of the valve cartridge assembly and allows valve operation or opening and closing through its rotation. The valve stem uses 2-3 stub Acme threads (2 major diameter, 3 threads per inch), which results in 1 of gate travel for every three rotations in one direction. The smaller threads, on the end opposite the Acme threads are used to fasten the valve cartridge to the insertion tool during the installation process and to secure the 2 square operating nut with a nut after valve insertion is complete. The valve stem is made from UNS S Stainless Steel per ASTM A582, which is compliant with the AWWA C standard. The following components are included in the valve stem assembly: O-Rings (2) Two Buna N o-rings fit into o-ring grooves above the ACME threads and create a redundant seal between the gate housing and valve stem Thrust Washers (2) Thrust washers are positioned above and below the shaft collar of the valve stem to reduce operating torque by providing a low friction surface the valve stem rotates against. Both thrust washers are made of Acetal. Operating Nut- The 2 square operating nut is secured the top of the valve stem though a stainless steel nut that thread on the end of the valve stem and down onto the operating nut. A steel lock washer with a galvanized finish is placed under the nut to keep tension on the threads to prevent the nut from loosening. The operating nut provides a means for the valve operator to input torque to rotate the valve stem. The operating is cast using ductile iron, as specified in AWWA C and is painted for corrosion resistance. Open left operating nut are painted black and open right operating nuts are painted red according to AWWA C Stem Nut: The stem nut is contained within the gate and is threaded onto the valve stem through its internal 2-3 stub Acme threads (2 minor diameter, 3 threads per inch). Within the gate, the stem nut is prevented from rotating when the valve stem is turned. With the stem nut fixed inside of the gate and threaded onto the valve stem, rotating the valve stem results in gate travel. The stem nut is made from UNS C95400 Aluminum Bronze per ASTM B148. Top Flange: The top flange fastens to the valve body flange to provide a cover for the valve and also serves as a stop for the valve 144 Tower Drive, Suite A Burr Ridge, IL

22 IVP 250 Valve Insertion System - 16 inch Nominal Size step during the closing of the valve. The top flange is made from steel per AWWA C207 and is epoxy coated black for rust protection. The following components are included in the blind flange assembly: Nuts and Bolts (16 of each) Sixteen nuts and bolts are used to fasten the top flange to the valve body flange. The nuts and bolts are made from 316 Stainless Steel. X-Ring An x-ring is contained within a groove in the inside diameter of the top flange and seals upon the valve stem to provide a backup to the valve cartridge seals. The x-ring is made of Buna-N Lip Seal A lip seal is pressed into the top of the top flange and seals upon the valve stem to keep debris outside of the valve. The lip seal is made of urethane and Buna-N. APPROVED BY: Name: Title: Date: / / 144 Tower Drive, Suite A Burr Ridge, IL

23 IVP 250 Valve Insertion System Product Cut Sheet 16 IVP PSI Rated Insertable Gate Valve ITEM DESCRIPTION MATERIAL 1 VALVE BODY CLAMP STAINLESS STEEL 2 VALVE BODY BRANCH STAINLESS STEEL 3 VALVE BODY FLANGE STEEL (PAINTED) 4 GATE* CAST NYLON 5 GATE HOUSING CAST NYLON 6 VALVE STEM** STAINLESS STEEL 7 STEM NUT ALUMINUM BRONZE 8 GATE SEALS EPDM 9 PADDLE SHIELD ALUMINUM (ANODIZED) 10 VALVE BODY GASKET BUNA-N 11 THRUST WASHERS (2) ACETAL 12 RETENTION PLATE ALUMINUM 13 COMPLETION PLUG ALUMINUM 14 TOP FLANGE*** CARBON STEEL (EPOXY COATED) 15 FLANGE NUTS AND BOLTS STAINLESS STEEL 16 VALVE BODY NUTS, BOLTS, AND WASHERS STAINLESS STEEL 17 OPERATING NUT**** DUCTILE IRON (PAINTED) 18 PINS (8) STEEL (ZINC PLATED)/ BUNA-N 19 PLUGS (8) STEEL (PAINTED) 20 GATE HOUSING O-RINGS (2) BUNA-N * CONTAINS STAINLESS STEEL HARDWARE ** SEALS: TWO BUNA-N O-RINGS *** SEALS: BUNA-N X-RING AND BUNA-N/URETHANE LIP SEAL **** SECURED TO VALVE STEM WITH STAINLESS STEEL NUT AND ZINC PLATED STEEL LOCK WASHER OPTIONS AVAILABLE: OPTIONS AVAILABLE Open Direction: Left(C.C.W.) Right(C.W.) APPROVED BY: Name: Title: Date: / / S. Cicero Avenue Alsip, IL CS-IVP