Exercising of valves and fire hydrants is a necessary but often time-consuming job. Mechanized and automatic exercisers reduce manual labor, and accompanying computerized systems simplify record keeping and analysis of valve condition, helping water utility managers plan repairs, replacements and upgrades.

The Spin Doctor hydraulic-powered valve and hydrant exerciser from Hurco Technologies Inc. is designed to enable quick and easy setup and to minimize operator fatigue and the risk of repetitive motion and other types of injuries. The unit can mount to a variety of vehicles, including pickup trucks (front or rear hitch), trailers, vacuum units, or off-road vehicles for remote right-of-way service.

It works in conjunction with the company’s Valve Star data collection system, which enables electronic entry of complete information about each valve and the exercising performed on each visit. The system automatically gives GPS positions on all valves and hydrants and is compatible with most mapping systems.

On May 19, Leo Baumgart, national sales manager with Hurco Technologies, led a demonstration of the equipment for the Water Utility in the Village of Menomonee Falls, Wis. Taking part were water maintenance technicians Louie Thon and Troy Bacon, and Eric McRoberts, representing Davies Water of Muskego, Wis., a Hurco distributor.

The village purchased a Spin Doctor unit in spring 2008 and plans to use it to exercise its 4,473 valves on a two-year rotation.

Walk-around

The demonstration included the village’s Spin Doctor unit and a demonstration model equipped with the Valve Star system, to which the village unit could be upgraded. The village unit is trailer-mounted. The system includes a 6.5-hp manual-start gasoline engine coupled to a hydraulic power pack.

The control console is mounted on a jointed arm designed for a wide range of motion and a reach of about 13 feet from the vehicle. This lets users reach multiple valves and hydrants in close proximity without repositioning the vehicle. Simple gas springs support the weight of the console, making it easy for users to move and position.

To exercise a valve, the user grasps two handles, positions the console directly over the valve, and mates a valve key with the square lug in the base of the console. The user moves a low-effort lever — up for close, down for open — to activate the hydraulically powered mechanism that turns the valve.

The console includes an analog gauge that reads out the torque level, a digital revolution counter with reset button, and a knob for adjusting torque up or down in accord with the difficulty of turning the valve. A hydraulic fluid bypass system keeps the unit from exceeding the preset torque level.

The demonstration unit supplied by Hurco was mounted on a pickup truck trailer hitch. It included a hydraulic power pack, 13.5-hp gasoline engine with electric start, and an alternator. It had the same jointed arm as the village unit, but the control console included the Valve Star system. This unit replaces the control lever on the right side of the console with a finger-operated joystick on the left side.

It also includes a data screen used for entering valve information and for adjusting system torque. A built-in GPS receiver automatically receives valve coordinates, which are stored in memory. Data from an exercising session is stored on a memory card for later transfer to the master valve maintenance database in the office.

Operators use a set of six function buttons on the right side to navigate between different information screens. A round knob on the right side of the screen lets users “click” around fields on the screen, and a dial function lets them change or add data. The round knob is also used for torque adjustment.

Operation

Thon and Bacon towed the village Spin Doctor unit to a quiet street a short distance from the Water Utility headquarters. Thon removed a valve cover in the street near a fire hydrant. Bacon pull-started the engine, and Thon maneuvered the control console on its jointed arm until it was over the 6-inch gate valve.

He deployed a valve key to engage the operating nut on the valve, then connected the key to the square fitting on the control unit. As he squeezed the control lever into the up position, the key turned, closing the valve. After 16 revolutions, he pulled the control lever down to reopen the valve.

Thon then swung the unit’s arm several feet to the curbside to demonstrate how the unit’s reach enables exercising of additional valves without moving the trailer. When Thon took his hands off the control panel handles, the panel remained in position, the arm supported by the gas springs.

Baumgart showed how turning the knob on the console left or right increases or decreases torque.

With the first phase of demonstration complete, Bacon and Thon moved the village’s Spin Doctor unit, and Baumgart backed the Hurco demonstration unit into position near the same valve. He fired up the engine with the electric start and moved the control console into position over the valve.

Because the mechanical functions of the system with the Valve Star head are essentially the same as for the village’s unit, Baumgart demonstrated the workings of the data screen. He used the function keys to show the series of screens. Users can take advantage of as few or as many data points as they wish — the more data, the more complete the information for future reference. Screens include:

Settings 1. Users can choose valve or hydrant, and enter the valve size and type, direction of operation (e.g. Open Left), actuator type, maximum torque, maximum rotation speed, and maximum revolutions.

Settings 2. Users can enter the valve manufacturer, bury depth, function, type of access, status (active or inactive), normal position, and operator identification. This screen also enables entry of any deficiencies noted and repairs required (See Figure 1). Location. This screen provides GPS coordinates, including elevation, and provides space where the user can enter an address or other location data.

Valve. This screen displays the actual exercising data: hydraulic pressure, flow, torque, cycles, and status. A valve icon shows the progress of opening and closing (see Figure 2 on the previous page). Here, a torque warning triggers an on-screen alert and a siren alarm if the pre-set torque level is exceeded. In addition, the computer automatically sets the number of revolutions according to the size of the valve and triggers audible and visual alarms when the operator approaches that number. This prevents valve damage.

If a valve is left in a partially closed position, the valve icon lights up red as a warning to operators to reopen it.

Observer comments

The Spin Doctor unit is a clear advantage over the heavy valve wrench that Thon and Bacon also carry in their service truck. “It saves us a lot of time and a lot of labor, as compared to needing two of us to turn a wrench to get a valve open,” Thon observed.

“The system won’t break the valve because it stops at the torque level that you set.” These benefits translate to greater productivity in the field and less risk of damage to assets.

The Valve Star unit simplifies the process of data collection by replacing handwritten forms with on-screen data collection, which transfers directly into a database for office use. Data fields on the various screens are simple to use, and it appears that operators could become proficient with minimal instruction.

A few modifications could make the system easier to use. The screen was difficult to read in moderately intense sunlight. More brightness, or a hood such as those used on video camera monitors, would make the screen more readable. (Of course, readability is not as critical for simple data entry as for making and recording pipe inspection observations).

The dial system for entering letters and numerals to record observations is somewhat cumbersome; some type of keypad would help. A laptop-style interface could make data handling easier, especially if the entire unit could be detached and carried to the office, reducing reliance on memory cards for data transfer.

Manufacturer/user comments

Baumgart notes that Hurco is continuously evaluating improvements to the system, including a sun shield for the Valve Star data screen. Also under exploration is a handheld computer interface.

He notes that data handling is already simple, as all valve data is saved to an SD memory card that can be taken to the office for download into a computer and entry to a database. “The system gives you a history of your valve exercising program,” he says. “Users can easily upload this data into any system that accepts a Microsoft Excel program. Most GIS and asset management programs accept Excel or Access-based information.”

­Tom Dimoff, water utility crew leader, reports that maintenance technicians were at first skeptical of the Spin Doctor unit, which replaced older electrically powered valve turners. On trying the unit, the technicians universally favored its hydraulic operation.

Dimoff notes that staff reductions are forcing his department to do more with less. He reports that valve exercising volume has doubled to about 75 valves per day since the utility put the Spin Doctor unit to work. “The guys are also reporting less fatigue and less elbow, back and shoulder pain,” says Dimoff. “That may translate to fewer workers’ compensation claims.”