specification for valves p-09-1001 rev0

I ,;g.. / J 0 1510312010 ISSUED FOR BID LAP'! ceEO

REV DATE DESCRIPTION PREPARED I I' CH,tKED APPROVED

A+a CC ENERGY DEVELOPMENT SAL (Oman Branch)

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TITLE

SPECIFICATION FOR VALVES I----

JOB NR. I DOCUMENT NR REV. DATE SHEET

ceED/D02/20l0 P·09·1001 0 15103/2010 1 of 29

File: Spcc lhcation for Va~es P·OS· 1001Il!vO

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DOCUMENT NR. P-09-1001

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TITLE SPECIFICATION FOR VALVES

File: Specification for Valves P-09-1001 rev0

SHEET REVISIONS SHEET REVISIONS 0

1 X 51 2 X 52 3 X 53 4 X 54 5 X 55 6 X 56 7 X 57 8 X 58 9 X 59

10 X 60 11 X 61 12 X 62 13 X 63 14 X 64 15 X 65 16 X 66 17 X 67 18 X 68 19 X 69 20 X 70 21 X 71

22 X 72 23 X 73 24 X 74 25 X 75 26 X 76 27 X 77

28 X 78 29 X 79 30 80 31 81 32 82 33 83 34 84 35 85 36 86 37 87 38 88 39 89 40 90 41 91 42 92 43 93 44 94 45 95 46 96 47 97 48 98 49 99 50 100


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INDEX

1. SCOPE ....................................................................................................................... 6

2. CODES AND STANDARDS ....................................................................................... 7

2.1 DESIGN ......................................................................................................................... 7

2.2 REFERENCED CODES ................................................................................................ 7

3. GENERAL DESIGN REQUIREMENTS ...................................................................... 9

3.1 GENERAL ..................................................................................................................... 9

3.2 PRESSURE SEALING OF BLOCK VALVES ................................................................. 9

3.3 FIRE TEST DESIGNS ................................................................................................... 9

3.4 VALVE OPERATION ..................................................................................................... 9

3.5 POSITION INDICATORS............................................................................................. 10

3.6 BACK SEATS .............................................................................................................. 10

3.7 STEMS ........................................................................................................................ 10

3.8 DRAINS, VENTS, FLUSHING CONNECTIONS .......................................................... 10

3.9 SOFT SEAT AND SEAL MATERIALS ......................................................................... 11

3.10 GLAND PACKING .................................................................................................... 11

3.11 BONNET GASKETS................................................................................................. 11

3.12 BONNET AND GLAND BOLTING ............................................................................ 11

3.13 BODY CAVITY RELIEF ............................................................................................ 11

3.14 ACTUATED VALVES ............................................................................................... 12

4. VALVE DESIGN ....................................................................................................... 13

4.1 GENERAL ................................................................................................................... 13

4.2 BALL VALVES ............................................................................................................. 13

4.3 DUAL PLATE WAFER CHECK VALVES ..................................................................... 14

4.4 INTEGRAL BLOCK AND BLEED VALVES .................................................................. 14


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5. END CONNECTIONS ............................................................................................... 15

5.1 FLANGED VALVES ..................................................................................................... 15

5.2 FLANGE DRILLING ..................................................................................................... 15

6. MATERIALS ............................................................................................................. 16

6.1 GENERAL ................................................................................................................... 16

6.2 BOLTING ..................................................................................................................... 16

6.3 CARBON STEEL AND LOW TEMPERATURE CARBON STEEL ................................ 16

6.4 AUSTENITIC STAINLESS STEELS ............................................................................ 17

7. IMPACT TESTING ................................................................................................... 18

7.1 GENERAL ................................................................................................................... 18

8. WELDING ................................................................................................................. 19

8.1 GENERAL ................................................................................................................... 19

8.2 WELD OVERLAYS ...................................................................................................... 19

9. INSPECTION AND TESTS....................................................................................... 20

9.1 NON-DESTRUCTIVE TESTING (NDT) ....................................................................... 20

9.2 HYDROSTATIC AND PNEUMATIC TESTING ............................................................ 21

9.3 FACTORY ACCEPTANCE TESTS .............................................................................. 22

9.4 NDT CERTIFICATION ................................................................................................. 22

10. MATERIAL CERTIFICATION ................................................................................... 23

10.1 GENERAL ................................................................................................................ 23

11. PREPARATION FOR SHIPMENT ............................................................................ 24

11.1 MARKING ................................................................................................................ 24

11.2 COLOUR CODING ................................................................................................... 24

11.3 PROTECTION .......................................................................................................... 24


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11.4 PAINTING ................................................................................................................ 24

12. PREPARATION FOR DISPATCH ............................................................................ 25

12.1 GENERAL ................................................................................................................ 25

12.2 PRESERVATION ..................................................................................................... 25

13. EXCEPTIONS TO SPECIFICATION ........................................................................ 26

14. SPECIAL PIPING ITEMS-VALVES .......................................................................... 27

14.1 SCOPE..................................................................................................................... 27

14.2 DESIGN ................................................................................................................... 27

14.3 IDENTIFICATION OF MATERIALS .......................................................................... 27

15. ACTUATION OF VALVES ....................................................................................... 28

16. HEALTH, SAFETY AND THE ENVIRONMENT ....................................................... 29


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1. SCOPE

This specification defines the minimum requirements for the design, materials, fabrication, inspection and testing of valves for piping systems designated for onshore facilitates.

This specification should be read in conjunction with the Piping Material Class Specifications and Valve Data Sheet specifications.


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2. CODES AND STANDARDS

The following codes, standards and statutory regulations shall be considered as part of this specification. It shall be the VENDOR’S responsibility to acquire possession of all required codes, standards and regulations referenced in this specification.

All valve design shall be as minimum meet the requirements of the latest edition of the codes and standards.

In the event of conflict between any of the codes and standards, requirements of the statutory authorities or with the requirements of this specification, the most stringent requirements shall take precedence.

All valves shall conform to the specifications for service as indicated on the valve data sheets and this specification. Any conflict shall be bought to the attention of the CONTRACTOR for conclusion prior to proceeding with the work.

2.1 DESIGN

ASME B31.3 Process Piping

NACE MR0175/ISO 15156 Materials for use in H2S containing environments in Oil and Gas Production

2.2 REFERENCED CODES

ASME B16.20 Metallic Gaskets for Pipe FLGS

ASME B16.21 Non-metallic Flat Gaskets for Pipe FLGS

ASME B16.10 Face to Face and End to End Dimensions of Valves

ASME B16.11 Forged Fittings, Socket Welding and Threaded

ASME B16.9 Factory Made Wrought Steel Buttwelding Fittings

ASME B16.34 Valves - FLG, THD and welding ends

API 6FA Specification for Fire Test for Valves

API 602 Compact Steel Gate Valves - FLG, THRD, Welding and Extended-Body Ends

API 598 Valves Inspection and Testing

API 607 Fire-Test for Soft Seated Quarter-Turn Valves

API 600 Bolted Bonnet Steel Gate Valves for Petroleum and Natural Gas Industries

API 594 Wafer and Wafer-Lug Check Valves

API 6D/ISO 14313 Pipeline Valves

MSS SP-25 Standard Marking System for Valves, Fittings, Flanges and Unions


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MSS SP-97 Integrally Reinforced Forged Branch Outlet Fittings - SW, THRD, BW

MSS SP-95 Swage Nipples and Bull Plugs

BS 2080 Face to Face, Centre to face, end to end and centre to end dimensions of valves

BS 4800 Schedule of paint colours for building purposes

BS 5493 Code of practice for protection of iron and steel structures against corrosion

BS 3958 Specification for Thermal Insulating Materials

BS 5422 Method for specifying Thermal Insulation of Pipework and Equipment

BS 5970 Code of Practice for Thermal Insulation of Pipework and Equipment

BS 1873 Steel Globe and Globe Stop and Check (FLG & BW)

BS 5352 Steel Wedge Gate, Globe and Check Valves < 50mm


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3. GENERAL DESIGN REQUIREMENTS

3.1 GENERAL

The VENDOR’S scope of supply shall consist of the design, production of materials, manufacturing, drawings and data, assembly, painting, testing, inspection and all VENDOR’S sub-supplier co-ordination, all in accordance with applicable codes and standards and any additional requirements of this specification.

3.2 PRESSURE SEALING OF BLOCK VALVES

All block valves shall be designed to seal in both directions i.e. bi-directional against all pressures up to maximum service pressure rating for the class unless specified otherwise.

3.3 FIRE TEST DESIGNS

Valves shall be fire-tested in accordance with BS6755 PTII.

The materials of construction or their design shall not vary from the fire test certificate unless approved by recognized certifying authority.

A fire test certificate for a particle size, class and type of valve shall be considered as qualification for accepting other valves in accordance with BS 56755 PTII.

A copy of the qualifying fire test certificates shall be included in the VENDOR’S bid.

3.4 VALVE OPERATION

Valve operation shall generally be in accordance with the Valve Data Sheets and the following table. The table is for Guidance only. The VENDOR shall guarantee that the maximum force to operate the valve shall not exceed 350N under full differential pressure. (Operating torque is defined as the force required to operate the valve under all conditions except “breakaway torque”.) In achieving this figure the maximum lever length shall be 450mm , and the maximum handwheel diameter shall be 750mm.

Consideration should be given to the “breakaway” torque (Break away torque is defined as the force required to unseat the valve in its first 10% of operator travel.) and the seating forces under maximum differential pressure. In no case shall this force exceed 350 N. If any of the above criteria cannot be achieved by using a lever/handwheel then a gearbox shall be fitted.

Lever operated valves shall be fitted with removable levers which shall fit parallel to the pipe when the valve is in the open position. Stems with a square top section are not acceptable. They shall be of the elongated pattern to prevent mis-orientation. Levers shall be rigidly constructed from carbon steel and a clockwise motion of the lever shall close the valve. Direction of closure shall always be indicated on the valves.

Gear operated valves shall have full enclosed rigid construction gearboxes that are capable of withstanding heavy use and are fully protected from an aggressive atmosphere and permit lubrication and maintenance. Clockwise rotation of the handwheel shall close the valve. Direction of closure shall be indicated on all valves.


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Components manufactured from flake graphite (grey) cast iron or aluminum alloys are not acceptable (ductile / nodular cast iron is acceptable).

As a general guide the following valves shall be gear operated:

Class Ball Gate Globe

150 8" and above 14" and above 8" and above



Valves shall be capable of satisfactorily operation with the valve stems in any position, i.e. vertical, horizontal, or inclined. The CONTRACTOR will define any valves required to have stems below horizontal. Valves shall be capable of operating in both the vertical and horizontal position unless stated otherwise on the Valve Specifications.

Uni-directional valves and check valves where the design is limited to sealing against flow or pressure from one direction and valves with a preferred direction for sealing, where such designs have been agreed with the CONTRACTOR, shall have a flow direction arrow integrally cast with the body.

All the above size demarcations are based on the valve closing fully and passing the seat leakage test using the maximum closing force stated above.

3.5 POSITION INDICATORS

Quarter turn valves with non-rising stem or valves with gear operators shall have position indicators, which cannot be wrongly orientated, either on initial assembly or during subsequent dismantling and reassemble. The position indicator shall be of a robust construction.

3.6 BACK SEATS

All valves of gate shall have back seats.

3.7 STEMS

All stems shall be blowout proof.

The maximum force or torque output from the valve operator, throughout the full range of the valve stroke, shall not exceed the allowable force or torque capability of the valve stem. The VENDOR may be called upon, to submit detailed calculations, and/or test results, verifying the valve stem design.

3.8 DRAINS, VENTS, FLUSHING CONNECTIONS

The requirements for vent, drain and flushing connections shall be as stated on the Valve Data sheets and shall comply with ASME B16.34.


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3.9 SOFT SEAT AND SEAL MATERIALS

All soft seat and seal materials shall be suitable for the service and minimum/maximum design and (or operating) temperatures/pressures, as stated on the individual Valve Data Sheets.

All soft seat and seal materials in classes 600 and above in hydrocarbon gas services shall be resistant to explosive decompression. All elastometric O-rings in hydrocarbon gas service in classes 600 and above to be limited to 6mm-diameter maximum. CONTRACTOR, as recommended by the VENDOR, shall consider alternative materials or grades/design of seta and seals, at bid stage.

3.10 GLAND PACKING

Gland packing shall be suitable for the service and conditions and shall take into account the requirements for low emission low maintenance service and shall be compatible with the stem material.

All packing shall be non-asbestos type.

Graphite packing shall be low to medium density, high purity, incorporating a passivating corrosion inhibitor and anti-extrusion elements.

VENDOR must ensure that any lubricated packing for low temperature duties shall not solidify or have any detrimental effect on the valve operation at the design temperatures specified.

Alternative packing arrangements may be submitted to CONTRACTOR for consideration at bid stage. These may include ‘squeeze type’ (with typically ‘o’ ring seal), ‘lip’ type (typically chevron) preloaded and pressure energized, ‘Thrust’ type (typically spring loaded) and ‘Diaphragm’ type. Several of these arrangements may be acceptable or, in some cases, preferred e.g. lip type are often superior to compression type.

3.11 BONNET GASKETS

All gaskets shall be compatible with all materials of construction, and suitable for the services and design conditions.

The body to bonnet connection shall be flanged and the flange facings shall be male-and-female or tongue-and-groove.

3.12 BONNET AND GLAND BOLTING

All bolting shall comply with what specified on the Valve Data Sheets and shall meet the requirements of ASME B16.34 paragraph 2.4. The VENDOR shall advise at the bid stage where bolting is below the minimum requirements (see ASME B16.34 paragraph 6.4).

3.13 BODY CAVITY RELIEF

All valves with body cavities except where the valve is to be used for double isolation applications are to be provided with a body cavity pressure relief facility to relieve high pressure that may exist due to temperature changes in fluids trapped in the body


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cavity. Where relief valves are fitted these shall be set between 1.1x and 1.3x the rated pressure and shall be fitted with an isolation block valve. Vendor to state how this is achieved at the bid stage.

3.14 ACTUATED VALVES

For actuated valves, actuators should be sized to provide a minimum torque of 1.5 times the value of the maximum torque at maximum differential pressure across the valve unless specified otherwise (see section 15.0 of this specification). The actuator shall be able to open and close the valve smoothly against the maximum differential pressure.

Valve stem designs shall not exceed normal allowable stress limits when applying normal maximum torque/force. There should be no damage or permanent deformation when applying maximum actuator output (e.g. stalled torque).

All actuator details shall be detailed on the actuator data sheets.

All valve bodies shall be strong enough to self support actuator regardless of valve actuator orientation, ESD actuators shall be able to with stand specified blast loads.


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4. VALVE DESIGN

4.1 GENERAL

Valves shall comply with the relevant Standards and Codes as specified in section 2.0

Valves shall normally meet the rating requirements of ASME B16.34. The VENDOR shall confirm at the bid stage the valve pressure/temperature rating. The VENDOR shall provide a pressure/temperature chart for all seat/seal materials.

All valve bodies are to be strong enough to accommodate the following end connection loadings with the design pressure and temperatue:

Flanged End Valves – Resultant Bending Stress 75MPa

All valves in process services shall meet NACE MR 0175/ISO 15156.

Where gate and globe valves are provided with packed glands stem finish shall be between 1.6 µm RA and 0.4 µm RA. Stuffing box bore finish shall be equal to or better than 3.2 µm RA. Stem, diameter under tolerance (see API 600) shall be 0.008” (5.16 mm) max. Stem run-out shall be equal to or better than 0.4 mm/m. Clearance between the gland follower and stuffing box bore shall be less than that between the gland follower and stem.

Valves shall be fully forged or cast to shape. Valves machined from barstock, plate or billet are not acceptable.

All VENDORS shall provide overall dimensions of valve and operators (manual or actuated) with their bid.

Fugitive emissions are to be minimized. VENDORS shall state in their bid, the design features that are incorporated in their design to ensure this requirement is met.

4.2 BALL VALVES

Ball valves up to and including 6” (150) N.B. Class 150 and Class 300 Ratings shall be double seated, floating ball (seat supported) design. Valves 8” (200) NB and larger Class 150 & Class 300 rating and 2”(50) NB and above in Class 600 rating and above shall be double seated bi-directional, trunnion mounted design.

All ball valves shall incorporate anti-blow-out stems and an anti-static device that ensure electrical continuity between body, stem and ball, and Valves shall be type-tested, the testing being carried out on new dry “as-built” valves of each type after pressure testing. The rest for electrical continuity shall be carried out after the test valve has been operated at least five times. It shall then be demonstrated that the discharge path between components has electrical continuity with a resistance not exceeding 1 ohm from a power source not exceeding 12V.

The VENDOR shall submit, with the bid, details of design and state accuracy of alignment of ball to bore of valve. Accuracy shall be maintainable to 0.25 mm (1”) up to 50 mm (2”) and to the lesser of 0.5 mm or 1 degree for sizes larger than 2”. Gear and manually operated Ball valves shall be equipped with stop limiting devices to prevent ball overtravel in the open and closed positions. The design shall provide for repeatable positive methods of accurately aligning the bores of valve components.


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Valves with hollow ball construction are not permitted.

Reduced bore ball valves shall be limited to one size reduction. Two size reduction may be allowed if detailed at the bid stage and agreed prior to order placement.

The VENDOR shall also select materials to minimize the effect of galvanic corrosion and galling, e.g. overlaying seat pockets, overlaying seals areas or overlaying fully wetted areas inclusive of through bore and gasket faces or grooves.

All ball valves shall be supplied with flanges for through bolting for attachment to vessels or piping flanges. Studded connection flanges are not acceptable.

Actuated valves shall have limit stops incorporated in the actuator design.

4.3 DUAL PLATE WAFER CHECK VALVES

All valves shall be suitable for horizontal or vertical (flow upwards) installation.

Valves with a lugged design shall have through drilled holes, which fully protect the bolting. Tapped holes are not acceptable.

Valves with a double flanged design are acceptable in lieu of a lugged design where significant weight and cost savings can be made. Face to face dimensions must remain the same. All VENDORS are to confirm at the bid stage which design for each size and rating is being offered.

Double flanged valves shall have flanged ends such that the length of bolts required for bolting to adjacent flanges are the same lengths as for a standard flange connection.

Both ‘retainer’ and ‘retainerless’ designs are acceptable. The ‘retainerless’ design shall be such that the pin keeper plates/inserts do not impinge on the gasket contact surface areas. The ‘retainer’ design shall incorporate a seal on all possible leak to atmosphere, to eliminate fugitive emissions.

4.4 INTEGRAL BLOCK AND BLEED VALVES

All integral valves shall consist of a single piece forging or be of a bolted construction. All forgings shall be forged close to the final shape and size.

Valves levers/handles shall not be used for pre-tensioning stem seals. Pre-tensioning shall be achieved by separate means, allowing the lever/handle to be removed without affecting the integrity of the stem seals.

Lever retaining nuts shall be positively locked or be of the self-locking type to prevent loosening by vibration.

Valves having two seats shall be provided with a means of relieving cavity over-pressure to the upstream side of the seat.

All vent valves shall be needle type.


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5. END CONNECTIONS

5.1 FLANGED VALVES

All flanged connections up to and including 24” N.B. (12” N.B. for Class 2500) shall be in accordance with ASME B16.5 Flanges 26” N.B. (14” N.B. for Class 2500) and larger shall be in accordance with ASME B16.47 Series “A.

Flange jointing faces shall have the following surface roughness in accordance with ASME B46.1. The surface roughness shall be verified by visual or tactile means with appropriate roughness comparison specimens.

Class 150 RF-ASME B16.5: Ra 6.3 to 12.5 µm

Class 300 & 600 RF-ASME B16.5: Ra 3.2 to 6.3 µm

Surface finishes specified in preceding paragraph are for matching the following gasket types:

Class 150 RF Flat Ring

Class 300/600 RF Spiral wound

5.2 FLANGE DRILLING

The relationship between the drilling parameters and the flange diameters shall comply with ASME B16.5

The holes shall be equispaced about the vertical and horizontal axes of the flange.


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6. MATERIALS

6.1 GENERAL

At the bid stage the VENDOR shall provide full details of all component materials and the material condition including procedures and qualification for overlays or any other surface treatment.

The VENDOR shall confirm that the materials offered are suitable for extended operation in the specified service. This is particularly important for valves in production fluid service.

All materials shall be new and clean and free from rust, mill scale, pits and defects.

When specifying materials the VENDOR shall give careful consideration to the prevention of galling and pick-up between bearing and sealing surfaces and any possible galvanic reactions between dissimilar materials.

6.2 BOLTING

All bolting shall be suitable for the full pressure/temperature range as stated on the valve data sheets.

If bolting is directly exposed to the process fluid it shall have at least the same resistance as the valve body material.

Where valves are specified for sour service, the bolting material shall meet the requirements of NACE MR0175/ISO 15156.

6.3 CARBON STEEL AND LOW TEMPERATURE CARBON STEEL

Carbon steel used for the manufacture of cast or forged valve bodies and components shall be produced in an electrical furnace, or by the basic oxygen process. The chemical composition of carbon and carbon manganese steel castings and forgings shall be restricted as follows -

All flanged carbon steel valves shall have a carbin content of 0.25% maximum (Check Analysis) or 0.23% (Ladle Analysis) and a carbon equivalent of 0.45% maximum (Check Analysis) or 0.43% maximum (Ladle Analysis).

The carbon equivalent (CE) based upon either ladle or product (if available) analysis shall be calculated using the formula:

CE = C + Mn + Cr+Mo+V + Cu+Ni 6 5 15

Where the material standard or certification does not include all of the above elements, and with CONTRACTOR approval, the following short formula may be substituted:

CE = C + Mn + 0.05 6


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All forged temperature carbon steel materials shall have a maximum sulphur content of 0.015% (by product analysis). Casting sulphur limits shall be submitted for approval. Where sour service is designated, all materials shall meet NACE MR 0175/ISO 15156.

6.4 AUSTENITIC STAINLESS STEELS

Austenitic stainless steel castings shall be produced from steel refined by the Argon Oxygen Decarbutisation (AOD) or the Vacuum Oxygen Decarburisation (VOD) process or acceptable equivalent.

Austenitic stainless steel valves shall be supplied in the solution-annealed condition.

The VENDOR shall provide manufacturer certification, which states the heat treatment condition of the finished component as being ‘solution annealed’. Failure to do so shall result in rejection of the material with the item being replaced at cost to the VENDOR.

All repair welds shall be solution annealed in accordance with the relevant product specification. The ferrite content of deposited weld material shall be 3%-10%.


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7. IMPACT TESTING

7.1 GENERAL

Where specified, impact testing of parent material, welds and heat affected zones shall mean Charpy V Notch type and shall be carried out using procedures and apparatus in accordance with ASTM A370. The frequency of testing shall be one test (3 specimens) for every heat.

Where due to the thickness of material, it is not possible to remove standard size Charpy specimens, sub-size specimens shall be used. The minimum energy values required for sub size specimens shall be the ration of the actual specimen width to that of a full size specimen multiplied by the full size specimen energy value.


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8. WELDING

8.1 GENERAL

Where welding, including weld repairs, is proposed to be carried out in the manufacture of the valve, all welding shall be subject to welding procedures in accordance with ASME IX as a minimum. All procedures shall be subject to CONTRACTOR’S approval prior to commencement of any welding. (All welding procedure specifications shall be qualified in accordance with the requirements of ASME IX for ASME B31.3 scope and API 1104 for ASME B31.4/B31.8 ‘Pipeline’ scope.)

Weld repair of forgings is not acceptable.

Welding of casting’s only acceptable for valve bodies and bonnets/cover plates, in accordance with the provisions of their respective specifications and subject to prior agreement by the CONTRACTOR. Repairs to all body castings by peening or impregnation are prohibited. All excavations shall be subject to MPI or DPI prior to welding. No repairs will be permitted to castings, which suffer through wall leakage during hydrostatic or gas testing.

For weld repair procedure qualification the VENDOR shall carry out any heat treatment, NDT, including hardness testing, and charpy impact testing in accordance with the material specification and as required by this specification.

Impact testing in accordance with Section 7.0 shall be performed for the weld metal fusion line and heat affected zone (+2mm and +5mm locations) when impact testing is specified for the parent material.

All welds, including repair welds, shall be subject to 100% MPI/DPI and 100% radiography or ultrasonic examination. Minor defects may be ground or blended out provided that minimum wall thickness requirement (including corrosion allowance) are not affected.

Repairs shall be post weld heat treated if required by the product specification and in all cases for valves in sour service and certified to NACE MR0175/ISO 15156.

8.2 WELD OVERLAYS

Satellite overlays shall be applied where so specified on the Valve Data Sheets. Grades of satellite or other fusion-bonded overlays, which may be proposed by the VENDOR including methods of application, shall be agreed with the CONTRACTOR at the bid stage. Note that all fusion-bonded overlays shall be machined or ground to a smooth finish.

Weld procedures and weld procedure qualifications for overlays including any post weld heat treatment shall be submitted at the bid stage.


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9. INSPECTION AND TESTS

9.1 NON-DESTRUCTIVE TESTING (NDT)

Valve castings and forgings shall be subject to inspection in accordance with the following requirements:

RATING SIZES INSPECTION REQUIREMENTS

Class 150 All To MSS-SP-55

Class 300 12” & below To MSS-SP-55

Class 300 14” & above To MSS-SP-55 and 10% selected at random to ASME/ANSI B16.34 Annex B. see Note

Class 600 6” & below To MSS-SP-55

To MSS-SP-55

Class 600 8” & above To MSS-SP-55 and 10% selected at random to ASME/ANSI B16.34 Annex B. See Note

Class 900 3” to 10” To MSS-SP-55 and 10% selected at random to ASME/ANSI B16.34 Annex B. See Note

Class 900 12” & above To MSS-SP-55 and to ASME/ANSI B1\6.34 Section 8, Annex ‘B’

Class 1500 2” & below To MSS-SP-55 and 10% selected at random to ASME/ANSI B16.34 Annex B. See Note

Class 1500 3” & above To MSS-SP-55 and to ASME/ANSI B16.34 Section 8, Annex ‘B’

Class 2500 2” & below To MSS-SP-55 and 10% selected at random to ASME/ANSI B16.34 Annex B. see Note

Class 2500 3” & above To MSS-SP-55 and to ASME/ANSI B16.34 section 8, Annex ‘B’

Note:

Random selection shall be per heat/quantity/size to be agreed between CONTRACTOR and VENDOR.


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In addition the machined surfaces of all High Alloy Steel valves, forged or cast, shall be subjected to 100% Dye Penetrant Examination in accordance with ASME B16.34 Anned “D”.

There shall be no linear defects > 3-mm. Any indication giving the appearance of a crack shall not be permitted.

To determine wall thickness, the CONTRACTOR’S Inspector will select castings and forgings at random. Valves selected shall provide assurance that the forgings/castings supplied will comply with the wall thickness requirements of the referenced specifications.

By prior approval, ultrasonic examination (UT) as an alternative to radiography for forgings will be accepted for Classes 150, 300 & 600.

9.2 HYDROSTATIC AND PNEUMATIC TESTING

All valves shall be high pressure hydrostatically body and seat tested and low pressure pneumatically seat tested in accordance with the requirements of BS6755 Part 1 and as shown on the individual valve data sheets. There shall be no body leakage.

The acceptance criteria for seat leakage shall be BS 6755 PT1 Rate ‘A’

A sample of each size/rating of split body valves where the joint is transverse to piep axis (e.g. ball valves) are to be hydro tested with blank flanges fitted to demonstrate that the joints will remains tight with a hydrostatic end load applied. In addition to the tests specified in the Valve Data Sheets, all valves in hydrocarbon service shall be subject to the following:

Valves selected for gas leak testing of the seats in addition to the body leak testing, shall have the 6.0 barg low pressure pneumatic seat test replaced by a 1.0 barg pneumatic seta test with the same acceptance criteria.

The removal and refitting, during or after test, of any pressure retaining components shall be covered in the test procedure and shall be verified by, and to the satisfaction of the CONTRACTOR’S inspector.

Hydrotest procedures shall include the following requirements additional to those specified by the BS6755 Part 1.

All soft seated valves shall be operated a minimum of three times in the dry condition, before commencement of the hydrotest.

The minimum duration of the body test shall be 15 minutes.

The minimum duration of the seat tests shall be 5 minutes.

Whilst carrying out the body test the valve shall be inspected for leakage through the stem packing. Any observable leak, which cannot be stopped by tightening, or at the discretion of the CONTRACTOR’S Inspector, shall be cause for reject.

All butterfly and dual plated check valves shall additionally be subjected to disc strength test, in accordance with BS 5155, which shall be performed prior to hydrostatic and pneumatic seat tests. Butterfly valves to be seat tested hydrostatically from both sided.

Hydrostatic tests shall be carried out using potable water containing 1% by volume of BP NID 260S liquid or other biodegradable wetting agent, at a minimum temperature of 7 °C.


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Maximum permitted chloride and fluoride content of water for hydrotesting purposes for stainless steel shall be 30 ppm. The PH value of the water shall be between 6 and 8.

All testing shall be carried out prior to the application of any primer or paint to the valves.

Castings shall not be impregnated with sodium silicate or similar materials to prevent leakage.

After completion of all seat hydrostatic testing, a torque test shall be carried out at full differential pressure, and measured torque’s recorded for seat breakout, mid and end range (See paragraph 3.4).

Body cavity pressure relief shall have been tested to ensure high pressures in the body cavity do not occur.

All valve body cavities shall be fully drained and thoroughly dried after completion of all hydrotests.

9.3 FACTORY ACCEPTANCE TESTS

All valves fitted with an actuator shall be subjected to a factory acceptance test. The test shall be in accordance with the details shown on the actuator data sheets.

9.4 NDT CERTIFICATION

The valve certification shall detail and contain all NDT results.


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10. MATERIAL CERTIFICATION

The Material Certification types and Traceability Levels shall be as stated on the relevant Data Sheets.

10.1 GENERAL

All metallic pressure containing components of the valves shall be certified to EN 10204-Type 3.1 or equivalent.

All other metallic components shall have material test reports.

All non-metallic components shall have a letter of conformity.

All mill certificates shall be originals or authenticated copies unless otherwise agreed with the CONTRACTOR.


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11. PREPARATION FOR SHIPMENT

11.1 MARKING

Body and Identification plates shall be legibly marked in accordance with relevant Code, Standard, Specification or MSS-SP-25 as appropriate.

The following additional markings shall be added to the permanently attached identification plate on each valve:

• Valve Tag Number or the S.P. Number

• Purchase Order Number

• Purchase Order Item Number

• Material Code Stock No.

11.2 COLOUR CODING

Colour Coding of valves is not required.

11.3 PROTECTION

After hydrostatic testing the internal surfaces of all valves shall be coated with a water displacing type of corrosion prevention oil/fluid which does not require solvent cleaning. To ensure total coverage the valve shall be placed into the half open position, filled with the fluid, then drained.

The ends of all valves shall be suitably protected against damage or ingress of dirt using plastic end capes or plywood/plastic discs (5 mm minimum thickness) as follows:

Butt weld ends: plastic caps – to be tight fitting and securely fixed with waterproof tape.

Flanges ends: plywood or plastic discs, to be bolted (minimum of 4 bolts) to the flange face or securely fixed to the flange face using waterproof tape.

11.4 PAINTING

All valves shall be coated in accordance with the Painting Specification


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12. PREPARATION FOR DISPATCH

12.1 GENERAL

Gate and globe valves shall be dispatched in the fully closed position.

Ball valves shall be dispatched in the fully open position.

In general, the dispatch of valves shall be in accordance with the VENDOR’S specification and/or the CONTRACTOR approved packing procedure.

12.2 PRESERVATION

All valve preservation shall be in accordance with the Vendor’s Preservation Procedure.

All valves shall be stored undercover in a dry atmosphere, in a safe position.

No packing end caps, plywood or plastic discs shall be removed until the valve is required for installation into the piping system.


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13. EXCEPTIONS TO SPECIFICATION

The VENDOR shall clearly define any exception to the scope of supply, specification, data sheets, referenced documents or supplier data requirements in his bid. Where the VENDOR has not brought to the attention of the CONTRACTOR of exception of any point, he shall comply in full.

All substitutions of materials must have prior approval from the CONTRACTOR.

However, alternative materials may be proposed where the VENDOR considers benefits would arise in performance, weight and cost. Full details of alternative materials shall be submitted to the CONTRACTOR at the bid stage, and agreed in writing by the CONTRACTOR.


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14. SPECIAL PIPING ITEMS-VALVES

14.1 SCOPE

This section covers the design of special piping valves. Items are designated as “special” because they are not included in or covered by both the Piping and valve Material Specifications or the Piping Engineering Standards.

14.2 DESIGN

Design and fabrication shall be in accordance with the special items data sheet all relevant codes, standards and specifications and all relevant Sections of this Specification.

14.3 IDENTIFICATION OF MATERIALS

All special items shall be “tagged” with a corrosion resistant metal plate, which shall be permanently and securely attached to the special item.

The “tag” number (e.g. SP-0000) and VENDOR’S serial number and purchasers code number shall be stamped on the plate in letters not less than 6 mm high.


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15. ACTUATION OF VALVES

The total design, manufacture and testing of the actuators and associated components shall be completely within the VENDOR’S responsibility.

The actuator shall be supplied in accordance with the instrument data sheets and this specification.

The valve torque used shall be those generated by the full differential pressure of the pipeline across the valve. Actuator minimum torque values shall be 2.0 times the required valve torque at maximum operating design conditions for all ESD and BDV valves and 1.5 times for all other valves. These requirements to be discussed further at bid stage. The valve and actuation torque valves shall be listed at the bid stage.

The actuator speed shall be controlled in accordance with the requirements shown on the valve actuator data sheets.

The actuator shall position the ball of the valve to accuracy of approximately 0.25 degrees on the open position and approximately 0.50 degree on the closed position.

The actuator shall be mounted directly on the valve without an extension. The VENDOR shall supply, if required, a mounting plate or mounting assembly for the actuator. The VENDOR shall confirm that the maximum actuator torque does not cause permanent deformation or damage. All actuated valves should be self-supporting regardless of actuator orientation.

End stops shall be provided. Mounting kits shall be designed to take account of the full reaction torque/forces available from the actuator.

Hydraulic System cleanliness shall be in accordance with NAS 1638.

Actuators shall be supplied with a sub-panel. The sub-panel shall generally be mounted on the valve, but remotely where access is restricted. Actuator assembly sub-panels will contain solenoid valves, tubing etc.


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16. HEALTH, SAFETY AND THE ENVIRONMENT

The VENDOR shall be required to demonstrate the existence of an adequate Management System, which will be applied during the performance of the work.

The VENDOR shall demonstrate (in the form of Health and Safety Plan) that he has identified all components and systems (within the design of his sub-suppliers equipment) and all operations (e.g. testing, installation, maintenance, commissioning, operation and decommissioning) that involve actions that may pose a safety hazard to the operator and others exposed.

The VENDOR shall demonstrate (in the form of an Environmental Plan) that he has identified any substances or actions that may pose a threat to the environment and how, in the event of an operational accident discharge, such an event can be managed.

All VENDORS are requested to offer any measures that can be taken to strive towards the environmental challenge of minimizing discharges and emissions, and adopt top quartile technology, at the bid stage prior to optimization and purchase order placement. VENDORS are expected to identify any emission sources and, if available, offer alternative means of reducing these emissions.

specification for valves p-09-1001 rev0

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