AWWA C509-01 Resilient-Seated Gate Valves For Water Supply Service

American Water Works Association
ANSUAWA C509-O1
(Revision of ANSVAWWA C509-94)
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AWWA STANDARD
FOR
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RESILIENT-SEATED GATE VALVES
FOR WATER SUPPLY SERVICE
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Effectivedate: Sept. 1,2001.

First edition approved by AWWA Board of Directors Jan. 28, 1980.
This edition approved Jan. 21, 2001.
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Approved by American National Standards Institute July 3,2001.
AMERICAN WATER WORKS ASSOCIATION

6666 West Quincy Avenue, Denver, Colorado 80235
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COPYRIGHT American Water Works Association

Licensed by Information Handling Services
A W A 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, certifi, or
approve any product. The use of AWWA'standards is entirely voluntary. AWWA standards are
intended to represent a consensus of the water supply industry t h a t the product described will
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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 t h e month of Journal AWWA
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publication of the official notice.
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American National Standard
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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 a n American National Standard does not in any
respect preclude anyone, whether that person has approved the standard or not, from manufactur-
ing, marketing, purchasing, or using products, processes, or procedures not conforming to the
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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 a n American National
Standard are encouraged to state on their own responsibility in advertising and promotional
materiais or on tags or labels that the goods are produced i n conformity with particular American
National Standards.
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CAUTIONNOTICE: 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, 11W. 42nd St., New York, NY 10036;
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(212) 642-4900.
All rights reserved. No part of this publication may be reproduced or transmitted in any form or by
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permission of the publisher.
Copyright O 2001 by American Water Works Association

Printed in USA
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Committee Personnel
The C509 Subcommittee, which developed this standard, had the following
personnel at that time:
Thomas J. Mettler, Chair
Jerry Bottenfield, Clow Valve Company, Oskaloosa, Iowa (AWWA)

L.R. Dunn, U.S. Pipe & Foundry Company, Birmingham, Ala. (AWWA)
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L.W. Fleury Jr., Mueller Group, Smithfield, R.I. (AWWA)
T.R. Ingalls, East Jordan Iron Works Inc., East Jordan, Mich. (AWWA)
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R.L. Larkin, American Flow Control, Birmingham, Ala. (AWWA)
Randy Looney, American AVK Company, Fresno, Calif. (AWWA)
T.J. Mettler, Waterous Company, South St. Paul, Minn. (AWWA)
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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:
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Joseph J. Gemin, Chair
Roland L. Larkin, Secretary
Consumer Members
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S.K. Batra, Detroit Water & Sewerage Department, Detroit, Mich. (AWWA)
M.O. Beagle, Lansing Board of Water & Light, Lansing, Mich. (AWWA)
T.M. Bowen, Manchester Water Works, Manchester, N.H. (AWWA)
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M.H. Burns, Denver Water Department, Denver, Colo. (AWWA)

C.H. Kersey, Tucker Young Jackson Tul1 Inc., Detroit, Mich. (AWWA)
S.D. Tucker, Los Angeles Department of Water and Power,
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Los Angeles, Calif (AWWA)
General Interest Members
R.L. Claudy Jr., Orlando, Fla.

C.R. Dugan, Council Liaison, Lansing Board of Water & Light,
Lansing, Mich.
J.V. Fonley, Orange, Calif.
J.J. Gemin, Earth Tech, Kitchener, Ont.
...
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S.J. Medlar, Camp, Dresser & McKee Inc., Edison, N.J. (NEWWA)
M.S. Solomon, Winzler Kelly Consulting Engineers, Santa Rosa,
Calif.
E.F. Straw, Insurance Services Office Inc., Duluth, Ga.
T.R. Volz, URS Greiner Inc., Colorado Springs, Colo.
J.H. Wilber,* Standards Engineer Liaison, AWWA, Denver, Colo.
Kenneth Zastrow, Underwriters Laboratories Inc., Northbrook, Ill.
Producer Members
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Jerry Bottenfield, Clow Valve Company, Oskaloosa, Iowa
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L.R. Dunn, US. Pipe & Foundry Company, Birmingham, Ala.
Les Engelmann, Ames Company Inc., Woodland, Calif.
L.W. Fleury Jr., Mueller Company, Cranston, R.I.
T.R.Ingalls, East Jordan Iron Works Inc., East Jordan, Mich.
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R.L. Larkin, American Flow Control, Birmingham, Ala.
Randy Looney, American AVK Company, Fresno, Calif.
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* Liaison, nonvoting
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Contents
All AWWA standards follow the general format indicated subsequently. Some variations from this f o m a t may be
found in a particular standard.
SEC. PAGE SEC. PAGE
Foreword 5 Verification
5.1 Proof of Design Testing...................... 17
I Introduction. ....................................... vii
5.2 Production Testing ............................. 17
1.A Background ......................................... vii
Plant Inspection and Rejection ......... 18
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5.3
1.B History ................................................ vii
1.C Acceptance .......................................... vii 6 Delivery
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II specialIssues .................................... viii 6.1. Marking ............................................... 18
...
111 Use of This Standard........................ V111 6.2 packaang and Shipping .................... 18
II1.A Purchaser Options and 6.3 Afndavit of Compliance...................... 19
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Alternatives ....................................... ix
1II.B Modification to Standard...................... x Appendixes
IV Major Revisions..................................... x
V Comments. ............................................. x A Installation, Operation, and
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Maintenance of Resilient-Seated
0 St a n d a r d Gate Valves.................................... 21
1 General
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Tables
1.1 Scope ...................................................... 1
1 Minimum Thickness of Body
1.2 Purpose .................................................. 2
and Bonnet ......................................... 9
1.3 Application............................................. 2
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2 Excess Flange Thickness .................... 10

2 References........................................... 2 3 Copper Alloys for Stem, Stem Nut,
3 Definitions........................................... 4 and Copper Alloy Gates .................. 11
4 Minimum Diameter of Stem and
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4 Requirements
Minimum Number of Turns
4.1 Data to Be Supplied by the to Open ............................................. 13
Manufacturer ..................................... 5 5 Outside Diameter of
4.2 Materials................................................ 5 Handwheels ..................................... 15
4.3 General Design ...................................... 8 6 Gear Ratios ......................................... 16
4.4 Detailed Design ..................................... 8
4.5 Fabrication .......................................... 16

Foreword
This foreword is for information only and is not a part of AWWA (2509.
I. Introduction.
I.A. Background. The resilient-seated gate valve has been commonly used in
several European countries for many years. This type of valve has proven t o be
satisfactory in water utility applications. A resilient-seated gate valve similar to the
European model was introduced into the US and has been in service in various water
utility applications since 1975.
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I.B. History. The American Water Works Association (AWWA) requested the
assistance of the Manufacturers Standardization Society of the Valve and Fittings
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Industry (MSS) in providing a standard for resilient-seated gate valves a t the 1976
AWWA annual conference.
MSS has played an important role in the development of this standard. The
organization was created in 1924, and in 1930, it organized the MSS Water Works
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Committee and designated representatives for appointment to AWWA standards
committees. Since that time, MSS has been particularly active and effective in
developing new standards for the water utility industry and in making periodic
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revisions to existing standards.
I.C. Acceptance. In May 1985, USEPA entered into a cooperative agreement
with a consortium led by NSF International (NSF) t o develop voluntary third-party
consensus standards and a certification program for all direct and indirect drinking
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water additives. Other members of the original consortium included the American
Water Works Association Research Foundation (AWWARF) and the Conference of
State Health and Environmental Managers (COSHEM). The American Water Works
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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
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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
*Persons in Canada, Mexico, and non-North American countries should contact the
appropriate authority having jurisdiction.
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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, ANSI*/NSFt 60,
Drinking Water Treatment Chemicals-Health Effects, and ANSUNSF 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.
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Various certification organizations may be involved in certifying products in
accordance.with ANSINSF 61. Individual states or local agencies have authority to
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accept or accredit certification organizations within their jurisdiction. Accreditation
of certification organizations may vary fiom jurisdiction t o jurisdiction.
Annex A, “Toxicology Review and Evaluation Procedures,’’ t o ANSUNSF 61 does
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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
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guidelines (noncarcinogens) and risk characterization methodology (carcinogens). Use
of Annex A procedures may not always be identical, depending on the certifier.
AWWA C509-O1 does not address additives requirements. Thus, users of this
standard should consult the appropriate state or local agency having jurisdiction in
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order to
1. Determine additives requirements including applicable standards.
2. Determine the status of certifications by all parties offering to certify
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products for contact with, or treatment of, drinking water.

3. Determine current information on product certification.
II. Special Issues. This standard has no applicable information for this
section.
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III. Use of This Standard. AWWA has no responsibility for the suitability o r
compatibility of the provisions of this standard to any intended application by any
*American National Standards Institute, 25 W. 43rd St., New York, NY 10036.

t N S F International, 789 N. Dixboro Rd., Ann Arbor, MI 48105.
$Both publications available from National Academy of Sciences, 2102 Constitution Ave.
N.W., Washington, DC 20418.
...
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user. Accordingly, each user of this standard is responsible for determining that the
standard’s provisions are suitable for and compatible with that user’s intended
application.
1II.A. Purchaser Options and Alternatives. This standard includes certain
options that, if desired, must be specified by the purchaser. Also, several items must
be specified to describe completely the gate valve required.
The following items should be included in the purchaser’s specifications.
1. Standard used-that is, AWWA C509, Standard for Resilient-Seated Gate
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Valves for Water Supply Service, of latest revision.
2. Size and type of valve-NRS or OS&Y (Sec. 1.1).
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3. Whether the valve is handwheel or wrench nut operated and direction in
which handwheel or wrench nut shall turn to open (Sec. 4.4.7).
4. Catalog data, net weight, and assembly drawings to be provided by the
manufacturer (Sec. 4.11,if required.
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5. Midavit of compliance (Sec. 6.3),if required.
6. Quantity required.
7. Whether records of tests specified in Sec. 5 are to be provided.
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8. Whether the valve will be subjected to water that promotes galvanic
. corrosion and requires the use of alternative materials as described in Sec. 4.2.2.4.3.
9. Type of valve ends-flanged (Sec. 4.4.1.4.1),tapping valve flange
(Sec. 4.4.1.4.4),mechanical joint (Sec. 4.4.1.4.2),or push-on joint (Sec. 4.4.1.4.3).
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10. Type of stem seal-stuffing box or O-ring (Sec. 4.4.6.1).

11. Detailed description of wrench nut if not in accordance with Sec. 4.4.7.
12. Special cast markings (Sec. 6.1),if required.
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13, Whether bolting other than that specified by ASTM* A307 is required. It is
recommended that the purchaser veris. with the supplier whether specified or
requested alternate bolting materials are appropriate. What alternative, if any, is
desired in the type of rustproofing for bolts and nuts (Sec. 4.4.4).
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14. Cutter diameter must be specified for tapping valves (Sec. 4.3.2).Tapping
machine shell cutters are made in either “full size” (OD is full nominal size) or
“undersize” (OD is less than full nominal size, i.e., usually / / in. less [Reference
MSS SP-1131).
*American Society for Testing and Materials, 100 Barr Harbor Dr., West Conshohocken, PA
19428-2959.
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15. Whether gearing is required (Sec. 4.4.9).
16. Special packaging for shipment as may be required for protection of
coatings.
17. Whether the pH level of the water is less than 6.5 o r greater than 8.5.
1II.B. Modification to Standard. Any modification to the provisions, defmi-
tions, or terminology in the standard must be provided in the purchaser’s
specifications.
IV. Major Revisions. The major revisions made to this standard in this
edition include the following:
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1. The size range was increased to include the 24- and 30-inch sizes (Sec. 1.1.1).
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2. Identification of copper alloys was added (Sec. 4.2.2.4.1).
3. The acceptance clause (Sec. 1.C) has been revised to approved wording.
4. Section 1.2, Purpose, and Sec. 1.3, Application, were added.
5 . Table 3 was modified to include the UNS classification of bronzes in place of
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the letter grade of bronzes.
V. Comments. If you have any comments or questions about this standard,
please call the AWWA Volunteer & Technical Support Group, (303) 794-7711
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ext. 6283, FAX (303) 795-7603, or write to the group at 6666 W.Quincy Ave., Denver,
CO 80235.
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American Water Works Association
ANWAWWA C509-O1
(Revision of ANSVAWWA C509-94)
AWWA STANDARD FOR
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RESILIENT-SEATEDGATE VALVES
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FOR WATER SUPPLY SERVICE
Sec. 1.1 Scope w.

SECTION 1: GENERAL
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This standard describes iron-body, resilient-seated gate valves with nonrising
stems (NRS) and outside screw-and-yoke (OS&y> rising stems, includhg tapping gate
valves, for water supply service having a temperature range of 33"-125"F (0.6"-52"C).
These valves are intended for applications where fluid velocity does not exceed 16 Wsec
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when the valve is in fU open position.

1.1.1 Sizes. Gate valves described by this standard are 3-in. (75-mm), 4411.
(100-mm), 6-in. (150-mm), 8-in. (200-mm), 10-in. (250-mm), 12-in. (300-mm), 16-in.
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(400-mm), 20-in. (500-mm), 24-in. (600-mm), and 30-in. (750-mm) nominal pipe size
(NPS). Sizes refer to the nominal diameter, in inches (or millimeters), 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
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shall be 200 psig (1,380 kpa [gauge]) for 3- through 12-in.(75- through 300-mm) sizes
and 150 psig (1,034 Wa [gauge]) for 16- through 30-in. (400-through 750-mm) sizes.
1.1.3 Conditions and materials not described. This standard is not intended
to cover special conditions of installation or operation, such as built-in power drive,
installation in vertical or steeply inclined lines, conveyance of unusually corrosive
water, or excessive water hammer. These conditions are beyond the intended scope of
this standard and require special consideration in design and construction. Joint

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2 AWWAC509-O1
accessories for end connections, such as bolts, gaskets, glands, follower rings, and so
forth, 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 resilient-seated gate valves for water
supply service, including materials, application, inspection, handling, and shipping.
Sec. 1.3 Application

This standard can be referenced in specifications for purchasing and receiving
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resilient-seated gate valves and can be used as a guide for fabricating and
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assembling resilient-seated gate valves for water supply service. The stipulations of
this standard apply when this document has been referenced and then only to
resilient-seated gate valves for water supply service applications.
SECIION 2:
w. REFERENCES
This standard references the following documents. In their latest editions, they
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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* AS-568A-Aerospace Size Standard for O-rings.
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ANSUASME? B16.l-Cast Iron Pipe Flanges and Flanged Fittings.

ANSIíASME B16.10-Face-To-Face and End-To-End Dimensions of Valves.
ANSUASME B18.2.1-Square and Hex Bolts and Screws Inch Series.
ANSVAWWA CllO/A21.10-American National Standard for Ductile-Iron and
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Gray-Iron Fittings, 3 In. Through 48 In. (75 mm Through 1,200 mm), for Water.
ANSIíAWWA Clll/A21.ll-American National Standard for Rubber-Gasket
Joints for Ductile-Iron Pressure Pipe and Fittings.
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ANSIíAWWA C550-Standard for Protective Epoxy Interior Coatings for Valves

and Hydrants.
ANSIíAWWA C6OO-Standard for Installation of Ductile-Iron Water Mains and
Their Appurtenances.
*Amencan National Standards Institute, 25 W. 43rd St., New York, NY 10036.

tAmerican Society of Mechanical Engineers, 3 Park Ave., New York,NY 10016.

RESILIENT-SEATEDGATE VALVES 3
ASTM* A27-Standard Specification for Steel Castings, Carbon, for General

Application.
ASTM A126-Standard Specification for Gray Iron Castings for Valves, Flanges,
and Pipe Fittings.
ASTM A153-Standard Specification for Zinc Coating (Hot-Dip) on Iron and
Steel Hardware.
ASTM A307-Standard Specification for Carbon Steel Bolts and Studs, 60,000
PSI Tensile Strength.
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ASTM A395-Standard Specification for Ferritic Ductile Iron Pressure-
Retaining Castings for Use at Elevated Temperatures.
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ASTM A536-Standard Specification for Ductile Iron Castings.
ASTM B62-Standard Specification for Composition Bronze or Ounce Metal
Castings.
ASTM B98-Standard Specification for Copper Silicon Alloy Rod, Bar, and
Shapes.
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ASTM B124-Standard
Bar, and Shapes.
Specification for Copper and Copper Alloy Forging Rod,
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ASTM B 1 3 8 4 t a n d a r d Specification for Manganese Bronze Rod, Bar, and
Shapes.
ASTM B 1 5 A t a n d a r d Test Method for Mercurous Nitrate Test for Copper and
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Copper Alloys.
ASTM B584-Standard Specification for Copper Alloy Sand Castings for
General Applications.
ASTM B633-Standard Specification for Electrodeposited Coatings of Zinc on
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Iron and Steel.

ASTM B763-Standard Specification for Copper Alloy Sand Castings for Valve
Application.
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ASTM B766-Standard Specification for Electrodeposited Coatings of

Cadmium.
ASTM B824-Standard Specification for General Requirements for Copper Alloy
Castings.
ASTM D395-Standard Test Methods for Rubber Property-Compression Set.
*American Society for Testing and Materials, 100 Barr Harbor Dr., West Conshohocken, PA
19428-2959.

4 AWWAC509-O1
ASTM D429-Standard Test Methods for Rubber Property-Adhesion to Rigid

Substrates.
ASTM D47 1-Standard Test Method for Rubber Property-Effect of Liquids.
ASTM D1149-Standard Test Method for Rubber Deterioration-Surface Ozone
Cracking in a Chamber.
ASTM D2000-Standard Classification System for Rubber Products in Automo-
tive Applications.
Fed. Spec.* HH-P-106d-Packing; Flax or Hemp.
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Fed. Spec. TT-C-494b-Coating Compound, Bituminous, Solvent Type, Acid
Resistant.
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MSSt SP-9-Spot Facing for Bronze, Iron, and Steel Flanges.
MSS SP-60-Connecting Flange Joint Between Tapping Sleeves and Tapping
Valves.
MSS SP-113-Connecting Joint between Tapping Machines and Tapping Valves.
System (UNS).
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SAES HS-l086/ASTM DS-56F-Metals and Alloys in the Unified Numbering
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SECTION 3: DEFINITIONS
The following definitions shall apply in this standard:
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1. Cosmetic defect: A blemish that has n o effect on the ability of the

component to meet the structural design and production test requirements of this
standard. Should the blemish or the activity of plugging, welding, grinding, or
repairing of the blemish cause the component to fail these requirements, then the
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blemish shall be considered a structural defect.

2. Flanged joint: The flanged and bolted joint as described in AWWNANSI
CllO/A21.10 or ANSI B16.1, class 125.
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3. Manufacturer: The party that manufactures, fabricates, or produces

materials or products.
*Federal Specifications available from Naval Publications and Forms Center, 5801 Tabor Ave.,
Philadelphia, PA 19120.
?Manufacturers Standardization Society of the Valve and Fittings Industry, 127 Park St. N.E.,
Vienna, VA 22180.
$Society of Automotive Engineers, Inc., 400 Commonwealth Drive, Warrendale, PA 15096-0001.

RESILIENT-SEATED GATE VALVES 5
4. Mechanical joint: The gasketed and bolted joint as described in

ANSIIAWWA C 111lA21.11.
5 . NPS: Nominal pipe size.
6. Purchaser: The person, company, or organization that purchases any
materials o r work to be performed.
7 . Push-on joint: The single rubber gasket joint as described in ANSUAWWA
c 11UA21.11.
8 . Structural defect: A flaw that causes the component to fail the structural
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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
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the minimum wall-thickness requirement, or failure to meet production tests.
9. 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 o r under pressure.
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SECTION 4: REQUIREMENTS ~ ~~
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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 iron-body, resilient-seated gate valves.
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4.1.1 Catalog data. The manufacturer shall supply catalog data, including
illustrations and a parts list that identifies the materials used for various parts. The
information shall be in sufficient detail t o serve as a guide in the assembly and
disassembly of the valve and for ordering repair parts.
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4.1.2 Weight information. The manufacturer shall provide a statement of the

net assembled weight for each size of valve exclusive of joint accessories.
4.1.3 Assembly drawings. The manufacturer or supplier shall submit to the
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purchaser one set of drawings showing the principal dimensions, construction details,
and materials used for all parts of the valve. All work shall be done and all valves
shall be provided in accordance with these drawings after the drawings have been
reviewed and accepted by the purchaser.
Sec. 4.2 Materials

. 4.2.1 General. Materials shall comply with the requirements of the Safe
Drinking Water Act and other federal, state and local requirements. Legislation is

6 AWWA C509-O1
subject to change. Therefore, it is the manufacturer’s and purchaser’s responsibility

to verify the current requirements of federal, state, and local regulations. When
reference is made to ANSI, ASTM, AWWA, or other standards, it shall be understood
that the latest revision thereof shall apply. All materials used in valves produced
according to this standard shall conform to the requirements stipulated in the
. following sections.
4.2.2 Mechanical and chemical properties. The requirements of ANSI, ASTM,
AWWA, or other standards to which reference is made in this text shall govern the
mechanical and chemical characteristics of the valve components. Whenever valve
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components are to be made in conformance with AWWA, ANSI, ASTM, or other
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standards that include test requirements or testing procedures, the manufacturer or
supplier shall comply with those procedures. The records of all tests shall, if required
by the purchaser’s specification, be made available to the purchaser.
4.2.2.1 Gray iron. Gray iron shall conform t o or exceed the requirements of
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ASTM A126 Class B.
4.2.2.2 Ductile iron. Ductile iron shall conform to the requirements of
ASTM A395 or ASTM A536. In addition, ductile iron shall contain no more than 0.08
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percent phosphorus.
4.2.2.3 Steel. Carbon-steel castings, when used, shall be ASTM A27 grade
U-60-30 or equal.
4.2.2.4 Copper alloys. Copper alloys used in valves shall comply with the
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following:
4.2.2.4.1 Copper alloy valve components shall be made to ASTM recognized alloy
specifications with Metal and Alloys in the Unified Numbering System (UNS)
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designations. Copper alloys are not limited to those specified in this standard. All
copper alloys, however, must meet the performance requirements of this standard,
including but not limited to minimum yield strength, chemical requirements, and
corrosion resistance.
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4.2.2.4.2 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.
4.2.2.4.3 Waters in some areas have been shown to promote galvanic corrosion
in the form of dezincification or dealuminization. Copper alloys which 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.

4.2.2.4.4 Copper alloys which contain more than 16 percent zinc shall not
contain less than 57 percent copper.
4.2.2.4.5 Copper alloys which contain 16 percent zinc or less shall not contain
less than 79 percent copper.
4.2.2.4.6 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.
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4.2.2.4.7 Copper alloys which contact drinking water shall comply with the
Safe Drinking Water Act.
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4.2.2.5 Gaskets. Gasket material shall be made of non-asbestos, inorganic
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mineral fiber, rubber composition, or paper that is free from corrosive ingredients.
O-rings or other suitable elastomeric seals may be used.
4.2.2.6 O-rings. O-rings shall meet the requirements of ASTM D2000 and
have physical properties suitable for the application.
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4.2.2.7 Packing. Stuffing-box packing shall be made of flax conforming to Fed.
Spec. HH-P-1O6d or other appropriate material. Hemp, asbestos, or jute packing shall
not be used.
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4.2.2.8 Coatings. Unless otherwise specified by the purchaser, valve coatings,
as required in Sec. 4.5.2, shall meet the performance requirements of Sec. 3.4.5 of
Fed. Spec. TT-C-494b for water-based enamel coating, or black asphalt coatings, or
ANSUAWWA C550 for epoxy coatings, or equal.
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4.2.2.9 Elastomers. Elastomers shall comply with the following:

a. Rubber seats shall be resistant t o microbiological attack, copper poison-
ing, and ozone attack.
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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
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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 the 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).

8 AWWA C509-O1
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. All parts of all valves shall be designed to withstand,
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without being structurally damaged, (1)an internal test pressure of twice the rated
design working pressure of the valve; and (2) the full-rated internal working pressure
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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 be capable of
withstanding an input torque as follows: 3-in. and 4-in. (75-mm and 100-mm) NPS-
NPS-300
manufacturer. w.
200 R.lb (270 Nm); 6 in. (150 mm), 8 in. (200 mm), 10 in. (250 mm), and 12 in. (300 mm)
R.lb (406 N-m).For sizes larger than 12 in. (300 mm), consult the
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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 shall
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include approplriate clearance for the diameter of the tapping machine cutter
recommended by the valve manufacturer. Some valves may require an undersized
cutter, which is smaller than the nominal diameter of the valve.
Sec. 4.4 Detailed Design

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4.4.1 Body and bonnet.

4.4.1.1 Material. The body and bonnet shall be made of gray iron or ductile
iron.
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4.4.1.2 Shell thickness. Shell thickness measurements taken at points dia-

metrically opposite to each other shall, when added together and divided by two,
equal or exceed the minimum metal thicknesses stated in Table 1. Shell thickness at
no point shall be more than 12.5 percent thinner than the minimum metal thickness
stated in Table 1, and no continuous area of deficient thickness shall exceed 12.5
percent of the pressure-containing shell area of the casting.

Table 1 Minimum thickness of body and bonnet
Valve Diameter Minimum Thickness*

NPS, in. (mm) in. (in.,fractions) (mm)
3 0.37
4 0.40
6 0.43
8 0.50
10 0.63
12 0.68
16 0.85
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20 0.97
24 1.08
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30 1.39
*The decimal value should be used when the t w o expressions are not exactly equivalent.
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4.4.1.3 Body seating surfaces. Resilient seats shall seat against a corrosion-
resistant 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
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equivalent to or better than bronze. A nonmetallic surface shall be in compliance with
ANSVAWWA C550.
4.4.1.4 Valve ends. End connections shall conform to one of the following
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requirements.
4.4.1.4.1 Flanged ends. The end flanges of flanged valves shall conform t o
dimensions and drillings of ANSI B16.1 Class 125 or ANSYAWWA CllO/A21.10
unless explicitly provided otherwise in the purchaser’s specifications. Unless spot-
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facing is required by the purchaser’s specifications, the bolt holes of the end flanges
shall not be spot-faced except when the thickness at any point within the spot-face
area, as deñned in MSS SP-9,exceeds the required minimum flange thickness of
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ASME/ANSI B16.1 by more than indicated in Table 2 or if the flange is not

sufficiently flat. If the foregoing limit is exceeded, either spot-facing or back-facing
may be used to meet the requirements. When required, all spot-facing shall be done
in accordance with MSS SP-9. Bolt holes shall straddle the vertical centerline of the
valve, unless otherwise specified by the purchaser. The laying lengths of flanged
valves 12 in. (300 mm) and smaller shall conform t o the requirements for double-disc
gate valves listed in Table 1of ANSVASME B16.10.

10 AWWA C509-O1
Table 2 Excess flange thickness
Nominal Valve Size Excess Thickness

NPS, in. (mm) in. (mm)
3-12 (100-300) 118 (3.2)
16-24 (400) 3/16 (4.8)
30 (750) 3 (6.4)
4.4.1.4.2 Mechanical-joint ends. Mechanical-joint bell dimensions shall con-

form to ANSUAWWA C111/A21.11. Slots with the same width as the diameter of the
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bolt holes may be provided instead of holes in the bell flange at those places where
the valve body or bonnet interfere with the joint assembly.
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4.4.1.4.3 Push-on joint ends. Push-on joints shall conform to the require-
ments of ANSUAWWA C111/A21.11.
4.4.1.4.4 Tapping-valve ends.
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a. 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, manufacturer, and supplier.
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b. The connecting end 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
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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,
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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.
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4.4.2.1 Material. The metal reinforcement of the gate shall be ductile iron,
gray iron, or copper alloy (see Table 3 for copper alloys).
4.4.2.1.1 Resilient seat. Resilient seats shall be bonded or mechanically
attached t o 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

Table 3 Copper alloys for stem, stem nut, and copper alloy gates
O ASTM SDecification Number

Copper AI~OY*
Allov Desimation
ASTM B16 UNS C36000
ASTM B138 UNS C67500

ASTM B283
Valve Stems ASTM B283 UNS C67600
ASTM B98 UNS C66100
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UNS C86500t
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UNS C86700t
UNS (387500
UNS CS7600
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UNS C86500t
UNS C86700t
UNS C99400
UNS C99500
ASTM B62 UNS C83600

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ASTM B824 UNS C84400t
Stem Nuts ASTM B124 UNS C37700

UNS C83450
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UNS C86700t

UNS C86700t
UNS C99400
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UNS C99500
~~ ~ ~ ~ ~~ ~ ~ ~ ~ ~~~ ~ ~
*Alloys actually used or specified not limited to those listed-see Sec. 4.2.2.4
t Compliance with AWWA C509 requires the manufacturer to specify minimum mechanical or chemical requirements that
exceed the minimums required for this alloy by the ASTM specification(s) listed.
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shall not be less than 75 lb/in. (13.2 N/mm). AU exposed mechanical attaching devices
and hardware used to retain the resilient seat shall be of a corrosion-resistant material.
4.4.3 Guides.
4.4.3.1 If guiding is required t o obtain shutoff, the design shall be such that
corrosion in the guide area does not affect sealing.

12 A W A C509-O1
4.4.4 Bolting. Bolting materials, excluding joint accessories, shall have the
mechanical strength requirements of ASTM A307 and shall have either regular
square or hexagonal heads with dimensions conforming to ANSI B18.2.1.Bolts,
studs, and nuts shall be (i)cadmium-plated (ASTM B766) or zinc-coated (ASTM
A153 or B633),or (2)made corrosion resistant by some other process disclosed to and
acceptable t o the purchaser. The purchaser may specifi bolts, studs, and nuts made
from a specified corrosion-resistant material, such as low-zinc bronze, nickel-copper
alloy, or stainless steel.
4.4.5 Stem, stem nut, and copper-alloy gates.
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4.4.5.1 Stems, stem nuts, and copper-alloy gates shall be made from a copper
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alloy as shown in Table 3.
4.4.5.1.1 Valve stems shall be made from copper alloys that have a yield
strength of 20,000psi (137,800kPa) or greater.
4.4.5.1.2 Stem nuts shall be made from copper alloys that have a yield
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strength of 14,000psi (95,000E a ) or greater.
4.4.5.2 NRS stems. The stem must have an integral thrust collar.
4.4.5.3 OS&Y stems. OS&Y valve stems shall be of sufficient length so as to
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be a t least flush with the top of the stem nut when the gate is fully closed. The design
shall be such as t o prevent any possibility of the gate leaving the stem or the stem
turning during the operation of the valve.
4.4.5.4 Threads. The threads of stems and stem nuts shall be of Acme,
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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 and in perfect line throughout the
lift of opening and thrust of closing the valve.
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4.4.5.5 Diameter. The minimum stem diameters and number of turns to open
shall be as shown in Table 4.
4.4.6 Stem sealing. The sealing system shall be designed to be watertight at
the rated working pressure of the valve.
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4.4.6.1 NRS valves.

4.4.6.1.1 Materials. A stem seal plate o r O-ring packing plate, if necessary,
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 properties suitable
for the application. Stem-seal plate bolts and nuts shall conform to the requirements
as specified in Sec. 4.4.4.

Table 4 Minimum diameter of stem and minimum number of turns to open

~ ~
Valve Size NRS Valves

Mínimum Diameter Minimum Minimum Diameter Minimum
of Stem Number'of of Stem Unthreaded Number of
(at base of thread)* Turns of Stem Section and Turns of Stem
to Open Thread ODt to Opent
NPS, in. (mm) in. (mm) in. ímm)
3 (75) 0.859 (21.82) 9 314 (19.1) 7
4 (100) 0.859 (21.82) 12 1 (25.4) 9
6 (150) 1.000 (25.40) 18 1 118 (28.6) 18
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8 (200) 1.000 (25.40) 24 1 'I4 (31.8) 25
10 (250) 1.125 (28.58) 30 1 318 (34.9) 31
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12 (300) 1.188 (30.18) 36 1 318 (34.9) 37
16 (400) 1.438 (36.53) 48 1 112 (38.1) 48
20 (500) 1.750 (44.451 40 2 (50.8) 40
24 (600) 1.969 (50.01) 48 2 'I4 (57.2) 48
30 (750) 2.188 (55.58) 60 2 'I2 (63.5) 60
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*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.
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$Values shown for 6- through 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- through 12-in. NPS inclusive.
4.4.6.1.2 Stem seal plate. On NRS valves, the stem opening, thrust-bearing
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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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4.4.6.1.3 Stem seal. When an O-ring or other pressure-actuated stem seal is

used, the design shall incorporate at least two such seals. The dimensions of the
O-rings shall be in accordance with SAI3 AS-568A.
4.4.6.2 OS&Y valves.
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4.4.6.2.1 Stuffing boxes. A stuffkg box shall be provided to contain stem

packing.
a. Stufig-box dimensions. Stuffing boxes shall have a depth not less than
the diameter of the valve stem. The internal diameter shall be large enough to
contain adequate packing to prevent leakage around the stem.

14 AWWA C509-O1
b. Installation. Stuffing boxes shall be packed properly and ready for

service when valves are delivered to the purchaser. Adjustment of stuffing-box bolts
may be required to seal leakage at the time of installation.
4.4.6.2.2 Packing glands, gland followers, gland bolts, and gland-bolt nuts. The
packing gland assembly shall be of solid, solid-bushed, or two-piece design. Followers
may be formed integral with the gland or as a separate item.
a. Packing glands. Packing glands shall be made of a copper alloy, synthetic
polymer, gray iron, or ductile iron.
b. Gland follower. If a gland follower is used, it shall be made of either
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ductile iron, gray iron, or a copper alloy.
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c. Packing-gland bolts and nuts. Gland bolts shall be made either of a
copper alloy or steel according t o Sec. 4.4.4. Gland-bolt nuts shall be made of a copper
alloy or stainless steel. Stainless steel nuts should not be used on stainless steel
packing gland bolts.
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4.4.6.3 Stem seal replacement.
4.4.6.3.1 NRS valves. 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.
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4.4.6.3.2 OS&Y valves. Design of the valve shall be such that the stuffing box
can be packed when the valve is in the fully open position and under pressure.
4.4.6.3.3 Caution. Stem seal or packing replacement under pressure is
hazardous and is not recommended.
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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
purchaser’s specifications, the wrench nuts shall be l15/i6-in.(49.2-mm) square at the
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top, 2-in. (50.8-mm) square at the base, and 13/4-in. (44.5-mm) high. The outside
diameter of handwheels shall not be less than those stated in Table 5. Nuts shall
have a flanged base on which shall be cast an arrow at least 2-in. (50.8-mm) long
showing the direction of opening. The word ”OPEN,” in ‘/2-in. (12.7-mm) or larger
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letters, shall be cast on the nut to indicate clearly the direction t o 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 t o
open the valve, with the word “OPEN” in Y2-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 readily
readable.

Table 5 Outside diameter of handwheels*
Size of Valve Minimum Diameter of Handwheel

NPS, in. ímm) in. ímm)
3 7 (178)
4 10 (254)
6 12 (305)
8 14 (356)
10 (250) 16 (406)
12 (300) 16 (406)
*For sizes larger than 12 in. (300 mm), consult the manufacturer.
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4.4.7.1 Operating mechanism. NRS valves are t o be supplied with wrench
nuts or handwheels. OS&Y valves are to be supplied with handwheels.
4.4.7.2 Direction of opening. The standard direction of opening is counter-
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clockwise as viewed from the top. Valves opening in the opposite direction (clockwise)
may be specified.
4.4.7.3 Method of securing. Wrench nuts or handwheels shall be secured by
mechanical means to the valve stem on NRS valves. Handwheels shall be secured by
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mechanical means to the stem nut on OS&Y valves.
’,.
4.4.7.4 Color coding. Wrench nuts and handwheels that’open the valve by
turning to the right (clockwise) shall be painted red, and wrench nuts and
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handwheels that open the valve by turning t o the left (counterclockwise) shall be
painted black.
4.4.8 Gaskets. Gaskets, O-rings, or other suitable elastomeric seals shall be
used on all flanged joints intended to be watertight.
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4.4.9 Gearing. If gearing is required, it should be specified by the purchaser.

4.4.9.1 Gears. Gears shall be accurately formed and smooth-running, with a
pinion shaft operating in a bronze, self-lubricating pr ,.permanently sealed anti-
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friction bearing.
4.4.9.2 Material. Geared valves shall be equipped with steel, ductile-iron, or
gray-iron gears. If a cast-iron gear is supplied, the pinions shall be steel. Material for
steel gears shall be ASTM A27 grade U-60-30or equal.
I ‘
4.4.9.3 Gear ratio. Gear ratios shall not be less than those shown in Table 6.
4.4.9.4 Gear cases. Valves having O-ring or V-type stem seals may have the
gear case attached directly to the valve. When geared valves are supplied, enclosed
gear cases are required unless specifically excluded by the purchaser’s requirements.

16 AWWAC509-O1 ’
Table 6 Gear ratios

Valve Diameter . Minimum Gear Ratio
NPS, in. (mm)
16 (400) 2:l
20 (500) 2:l
24 (600) 3:l
30 (750) 3:l
4.4.9.5 Indicators. When required by the purchaser’s specifications, means
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shall be provided to indicate the position of the gate in relation to the waterway for
geared valves.
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Sec. 4.5 Fabrication
4.5.1 Workmanship.
4.5.1.1 Interchangeable parts. All parts shall conform to their required
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dimensions and shall be free from defects that could prevent proper functioning of
the valve. When assembled, valves manufactured in accordance with this standard
shall be well-fitted and shall operate smoothly. All like parts of valves of the same
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model and size produced by the same manufacturer shall be interchangeable.
4.5.1.2 Castings. All castings shall be clean and sound, without defects that
will weaken their structure or impair their service. Plugging, welding, or repairing of
cosmetic defects is allowed. Repairing of structural defects is not allowed unless
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agreed to by the purchaser. Repaired valves shall comply with the testing
requirements of this standard after repairs have been made. Repairs within the bolt
circle of any flange face are not allowed.
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4.5.2 Coating.
4.5.2.1 Interior ferrous surfaces. A coating conforming to ANSVAWWA C550
shall be applied t o the interior ferrous surfaces of the valve body that will be in
contact with water. Other exposed interior ferrous surfaces, except finished or
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bearing surfaces, shall be coated with a material specified in Sec. 4.2.2.8.

4.5.2.2 Exterior ferrous surfaces. A coating material as specified in Sec. 4.2.2.8
shall be applied to all exterior ferrous surfaces except fasteners.

SECTION 5: VERIFICATION
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Sec. 5.1 Proof of Design Testing
5.1.1 Hydrostatic test. One valve of each size and class of a manufacturer’s
design shall be hydrostatically tested with twice the specified rated pressure applied to
one side of the gate and zero pressure applied to the other side. The test is to be made
in each direction across the gate. During this hydrostatic test, the manufacturer may
make special provisions t o prevent leakage past the seats. No part of the valve or
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gate casting shall remain visually deformed by the test. Leakage shall not be a cause
for failure.
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5.1.2 Torque test. A valve of each size shall be overtorqued in the closed and
open positions t o demonstrate that there is no distortion of the valve stem or damage
t o the resilient seat as evidenced by failure to seal at rated pressure. The applied
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torque shall be 250 ft-lb (340 N-m) for 3-in. (75-mm) and 4-in. (100-mm) NPS valves;
350 fi-lb (475 N m ) for 6-in. (EO-mrn),8-in. (200-mm), 10-in. (250-mm), 12-in. (300-mm)
NPS valves; and 400 ft-lb (545 N m ) for 16-in. (400-mm), 20-in. (500-mm) and 24-in.
(600-mm) NPS valves; and 500 ft-lb (600 N-m) for 30-in. (750-mm) NPS valves.
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Torque shall be directly applied to the valve stem.
5.1.3 Leakage test. One valve of each size shall be fully opened and closed to
a seal for 500 complete cycles with sufflcient flow that the valve is at the rated
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working pressure for the pressure differential at the point of closing. The valves shall
be drip-tight under rated pressure differential applied alternately to each side of the
gate after completion of the tests.
5.1.4 Hydrostatic shell. One valve of each size shall be tested to 2.5 times the
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rated working pressure with the gate in the open position. 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
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remain visibly deformed after the test.
Sec. 5.2 Production Testing

After manufacture, each gate valve shall be subjected t o operation and
hydrostatic tests at the manufacturer’s plant as specified in this section.
5.2.1 Operation test. Each valve shall be operated through a complete cycle to
ensure free and proper functioning of all parts in the intended manner. Any defects

18 AWWA C509-O1
in workmanship shall be corrected and the test repeated until satisfactory

performance is demonstrated.
5.2.2 Shell test. A hydrostatic test pressure equal to at least twice the rated
working pressure of the valve shall be applied t o each assembled valve with the gate
in the open position. The test shall show no leakage through, the metal, pressure-
containing joints, or stem seals.
5.2.3 Seat test. Each valve shall be tested from each direction at a minimum
of the rated working pressure t o prove the sealing ability of the valve from both
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directions of flow. The test shall show no leakage through the metal, pressure-
containing joints, or past the seat.
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Sec. 5.3 Plant Inspection and Rejection
All work performed in accordance with this standard, except proof of design
testing, shall be subject to inspection and acceptance by the purchaser. The purchaser
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shall at all times have access to all places of manufacture where materials are being
produced and tested. Any valve or part not conforming to the requirements of this
standard shall be made satisfactory or shall be rejected and repaired or replaced by
the manufacturer. Repaired valves must be acceptable t o the purchaser and
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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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SECIION 6: DELIVERY
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Sec. 6.1 Marking

Markings shall be cast on the bonnet or body of each valve and shall show the
manufacturer’s name or mark, the year the valve casting was made, the size of the
valve, and the designation of working water pressure, for example, “200W.”Special
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markings in addition to these can be supplied when specified by the purchaser’s

requirements on agreement between purchaser and manufacturer.
Sec. 6.2 Packaging and Shipping

Valves shall be complete in all details when shipped. The manufacturer shall
use reasonable care in preparing valves for shipment. Valves shall be drained before
shipment.

RESILIENT-SEATEDGATE VALVES 19
Sec. 6.3 Affidavit of Compliance

The manufacturer shall, when required by the purchaser’s specifications,
provide the purchaser with an affidavit stating that the valve and all materials used
in its construction conform to the applicable requirements of this standard and the
purchaser’s specifications, and that all tests specified therein have been performed
and all test requirements have been met.
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1
APPENDIX A
Installation, Operation, and Maintenance
of Resilient-Seated Gate Valves
This appendix is for information only and is not a part of AWWA C509.
SECTION A. 1 : GENERAL
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Resilient-seated gate valves form a significant component part of many fire-
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fighting or water-distribution systems. Failure of a resilient-seated gate valve in such
systems, either caused by faulty installation or improper maintenance, could result in
extensive damage and costly repairs. In addition, many resilient-seated gate valves are
installed in buried-service or underground applications. Problems with or malfunctions
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of the valves caused by 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
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to improper handling, storage, installation, operation, or maintenance procedures.
SECTION A.2: UNLOADING

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All valves should be unloaded carefully; a soft sling around the body is
recommended to prevent damage to the valve and its protective coating. Each valve
should be carefully lowered from the truck to the ground; it should not be dropped.
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Valves should not be lifted or unloaded using chains, slings, or forklift fork($
engaging the valve actuator or handwheel, or passing through the valve waterway. In
the case of larger valves, forklifts or slings around the body of the valve or under the
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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.
21

22 AWWA C509-O1
SECTION A.3: INSPECTION PRIORTO INSTALLATION

Resilient-seated gate valves should be inspected at the time of receipt for
damage in shipment. The initial inspection should verify compliance with specifica-
tions, direction of opening, size and shape of operating nut, number of turns to open
or close, and type of end connections. A visual inspection of the seating surfaces
should be performed to detect any-damage in shipment or scoring of the seating
surfaces. Inspection personnel should look for bent stems, broken handwheels,
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cracked parts, loose bolts, missing parts and accessories, and any other evidence of
mishandling during shipment. Each valve should be operated through one complete
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opening-and-closing cycle in the position in which it is to be installed.
SECTION A.4: STORAGE
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Whenever practical, valves should be stored indoors. If ,outside storage is

required, valves should be protected from the weather, sunlight, ozone, and foreign
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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
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material.
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SECTION A.5: INSTALLATION

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Instructions supplied by manufacturers should be reviewed in detail before

valves are installed. At the jobsite prior t o installation, each valve should be visually
inspected and any foreign material in the interior portion of the valve should be
removed. '1 detailed inspection of the valve as outlined in Sec. A.3 should be
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performed prior to installation.
Sec. A.5.1 Bolts

All bolts should be checked for proper tightness and protected by the installer to
prevent corrosion, either with a suitable paint, 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 t o prevent settling and excessive strain on the connection to the pipe. Piping
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systems should be supported and aligned to avoid damage to the valve.
A.5.2.2 A valve box o r vault should be provided for each valve used in a buried-
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service application. The valve box should be installed so as not to transmit shock
loads or stress to the valve. 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 such
other level as directed by the owner. Valve boxes should be designed so that a traffic
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load on the top of the box is not transmitted to the valve.
A.5.2.3 Valves buried in unusually deep trenches should have special provi-
sions for operating the valve. Either a riser on the stem to permit use of a normal key
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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
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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
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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
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and aligned to avoid damage to the valves. Valves should not be used to correct the
misalignment of piping.
Sec. A.5.4 Inspection

After installation and before pressurization of the valve, all pressure-containing
bolting (bonnet, seal plate, packing gland, and end connections) should be inspected
for adequate tightness to prevent leakage. In addition, an inspection should be made
for adequate tightness of all tapped and plugged openings to the valve interior.

24 A W A C509-O1
Proper inspection at this time will minimize the possibility of leaks after pressuriza-
tion of the piping system.
Sec. A.5.5 Hydrostatic testing

To prevent time lost searching for leaks, it is recommended that valve
excavations not be backfilled until after pressure tests have been made. After
installation, it is desirable t o hydrostatically 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,
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steps should be taken t o 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
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direction at differential pressures above the rated working pressure. It should be

noted that valves seat better at or near the rated working pressure of the valve. It is
also recognized that wear or foreign material may damage valve seating surfaces and
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may cause leakage (Ref. AWWA C600).
Sec. A.5.6 Records

Upon completion of the installation, valve location, size, make, type, date of
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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

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Resilient-seated gate valves should not be installed in applications or for service

other than those recommended by the manufacturer. The following subsections for
precautions are not all inclusive but will help avoid some application hazards.
a. Resilient-seated gate valves should not be installed in lines where service
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pressure will exceed the rated working pressure of the valve.

b. Resilient-seated gate valves should not be used for throttling service
unless the design is specifically recommended for that purpose or approved in
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advance by the manufacturer.

c. Resilient-seated gate valves should not be used in applications that are
exposed to freezing temperatures.
d. Pipe, fittings, and valves installed in underground pipelines 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 t o 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 unstable soils.
e. To prevent damage, 3-in. (75-mm) and 4-in. (100-mm) NPS resilient-
seated gate valves should not be operated with input torques greater than 200 fi-lb
(270 N-m). Gate valves 6-in. (150-mm) NPS t o 12-in. (300-mm) NPS should not be
operated with input torques greater than 300 fi-lb (406 N-m). For sizes larger than
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12 in., consult the manufacturer.
f. For tapping applications, tapping valves are recommended.
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SECTION A.6: INSPECTION AND MAINTENANCE
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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 designed to prevent a buildup of tuberculation or other
deposits that could render the valve inoperable o r prevent a tight shutoff. The
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interval of time between operations of valves in critical locations, or valves subjected
to severe operating conditions, should be shorter than that for less important
installations, but can be whatever time period is found to be satisfactory based on local
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experience. The number of turns required to complete the operation cycle should be
recorded and compared with permanent installation records to veriS. fidl gate travel.
When using portable auxiliary power actuators with input torque capacities
exceeding the maximum operating torques recommended in Sec. A.5.7g, extreme care
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should be taken t o avoid the application of excessive torque to the valve stem. If the
actuator has a torque-limiting device, it should be set below the values in Sec. A.5.7g.
If there is no torque-limiting device, the recommended practice is to stop the power
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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. A
recording system should be adopted that provides a written record of valve location,
condition, maintenance, and each subsequent inspection of the valve.

26 AWWA C509-O1
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, t o check for leakage at all joints, connections, and areas
of packing or seals. If leakage is observed, all defective O-rings, seals, gaskets, or end-
connection sealing members should be replaced. If the leakage cannot be corrected
immediately, the nature of the leakage should be reported promptly t o those who are
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responsible for repairs. If the valve is inoperable or irreparable, its location should be
clearly established to save time for repair crews. The condition of the valve and, if
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possible, the gate position, should be reported to personnel responsible for repairs. In
addition, fire departments and other appropriate municipal departments should be
informed that the valve is out of service.
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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
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entered in the permanent record. When a resilient-seated gate valve is inspected, an
entry should be made in the permanent record indicating the date of inspection and
condition of the valve. If repair work is necessary, it should be indicated, and on
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completion of the work, the nature of the repairs and date completed should be
recorded.
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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 has been reported. If
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repairs are t o be performed in the field, the repair crews should take a full
complement of spare parts t o the jobsite. Provisions should be made to isolate the
defective valve from water pressure and relieve internal trapped pressure prior t o
performing any corrective maintenance. Disassembly of the valve should be
performed 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
indicating that the valve is inoperable should be removed. In addition, fire
departments and other appropriate municipal departments should be informed of the
satisfactory repair of the valve.
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Printed on recycled paper.

1P-7.5M-43509-7/01-CM


AWWA C509-01 Resilient-Seated Gate Valves For Water Supply Service

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AWWA C509-01 Resilient-Seated Gate Valves For Water Supply Service

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American Water Works Association

Effectivedate: Sept. 1,2001.

Approved by American National Standards Institute July 3,2001.

AMERICAN WATER WORKS ASSOCIATION

COPYRIGHT American Water Works Association

Copyright O 2001 by American Water Works Association

COPYRIGHT American Water Works Association

Thomas J. Mettler, Chair

Jerry Bottenfield, Clow Valve Company, Oskaloosa, Iowa (AWWA)

M.H. Burns, Denver Water Department, Denver, Colo. (AWWA)

Los Angeles, Calif (AWWA)

General Interest Members

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

COPYRIGHT American Water Works Association

COPYRIGHT American Water Works Association

SEC. PAGE SEC. PAGE

2 Excess Flange Thickness .................... 10

COPYRIGHT American Water Works Association

Association (AWWA) and the Association of State Drinking Water Administrators

COPYRIGHT American Water Works Association

products for contact with, or treatment of, drinking water.

*American National Standards Institute, 25 W. 43rd St., New York, NY 10036.

COPYRIGHT American Water Works Association

10. Type of stem seal-stuffing box or O-ring (Sec. 4.4.6.1).

COPYRIGHT American Water Works Association

COPYRIGHT American Water Works Association

AWWA STANDARD FOR

Sec. 1.1 Scope w.

when the valve is in fU open position.

COPYRIGHT American Water Works Association

Sec. 1.2 Purpose

Sec. 1.3 Application

ANSUASME? B16.l-Cast Iron Pipe Flanges and Flanged Fittings.

ANSIíAWWA C550-Standard for Protective Epoxy Interior Coatings for Valves

*Amencan National Standards Institute, 25 W. 43rd St., New York, NY 10036.

COPYRIGHT American Water Works Association

ASTM* A27-Standard Specification for Steel Castings, Carbon, for General

Iron and Steel.

ASTM B766-Standard Specification for Electrodeposited Coatings of

COPYRIGHT American Water Works Association

ASTM D429-Standard Test Methods for Rubber Property-Adhesion to Rigid

1. Cosmetic defect: A blemish that has n o effect on the ability of the

blemish shall be considered a structural defect.

3. Manufacturer: The party that manufactures, fabricates, or produces

COPYRIGHT American Water Works Association

4. Mechanical joint: The gasketed and bolted joint as described in

4.1.2 Weight information. The manufacturer shall provide a statement of the

Sec. 4.2 Materials

COPYRIGHT American Water Works Association

subject to change. Therefore, it is the manufacturer’s and purchaser’s responsibility

COPYRIGHT American Water Works Association

4.2.2.9 Elastomers. Elastomers shall comply with the following:

b. Rubber-seat compounds shall contain no more than 8 parts per million

COPYRIGHT American Water Works Association

Sec. 4.3 General Design

Sec. 4.4 Detailed Design

4.4.1 Body and bonnet.

4.4.1.2 Shell thickness. Shell thickness measurements taken at points dia-

COPYRIGHT American Water Works Association

Table 1 Minimum thickness of body and bonnet

Valve Diameter Minimum Thickness*

ASME/ANSI B16.1 by more than indicated in Table 2 or if the flange is not

COPYRIGHT American Water Works Association