Wrp-spc-mte-gen-027-p4-0.pdf

Specification

I Status: 1M

Revision: P4-0

BI

WRP-SPC-MTE-GEN-02?

for the Technical Supply of Valves

Worley Parsons resources & energy

I Date: 23 June 2015

Page No 1

TANAP TRANS ANATOLIAN NATURAL GAS PIPELINE PROJECT

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Specification for the Technical Supply of Valves

Issued

Checked

Approved

by

by

by

Issued for Inter Discipline Check

HUSO

SHAG

WIGP

28-Jan-15

Issued for Review

HUSO

CARC

WIGP

IM

12-Mar-15

Issued as Approved

HUSO

CARC

WIGP

IMP

23-Jun-15

Issued as Approved for Purchase

Rev

Status

Date

P3-B

IDC

03-Dec-14

P3-C

IFR

P3-0 P4-0

Status Description

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TANAP Approval

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WorleyParsons Proje Yönetimi ve Mühendislik Limited Sirketi, Kizrlrrrnak Mah. Ufuk Üniversitesi Caddesi, Farilya Business Center No: 8/18 Kat: -1, Çukurambar - Ankara, Turkey. Tel: +903122037700 Fax: +903122037701 © Copyright 2014 WorleyParsons

The only controlled version of this document resides in the Document Management System. Any copies made of this document shall be considered uncontrolled.

Specification for the Technical Supply of Valves Revision: P4-0

Status: IAA

WRP-SPC-MTE-GEN-027

Date: 25 June 2015

Page 2 of 64

DISCLAIMER: This document is the property of TANAP DOĞALGAZ İLETİM A.Ş. (TANAP). The copyright is the property of WorleyParsons. The document is confidential and may not be reproduced or disclosed without TANAP’s prior written permission. No reliance on the document is authorized by WorleyParsons other than for the purpose for which it was prepared and WorleyParsons accepts no liability for any reliance on the document for any other purpose.

REVISION DESCRIPTION SHEET

Rev.

REVISION DESCRIPTION

DATE ISSUED

P3-B

IDC

03-Dec-14

First Issue for IDC Review

P3-C

IFR

28-Jan-15

Sections updated to cover project specific valve requirements

P3-0

IAA

12-Mar-15

Issued as Approved

UPDATE / AMENDMENT DETAILS

General – EPCM references corrected to state CLIENT/EPCM General – Word Auxiliary replaced with Ancillary Section 2.2: Abbreviation table updated Section 3.1: Requisition documentation included in the Order of Precedence table Section 3.4: Table of References updated Section 5.1: Requirements for the use of valves manufactured using plate materials Section 5.2: Statement modified for stem design suitability for the maximum imparted torque Section 5.3.3: Threaded end valves specified as not to be used in hydrocarbon service Section 5.3.4: Statement added specifying that VENDOR shall confirm the length of the pup-piece is suitable for subsequent welding operation, such that the valve is not damaged Section 5.4: Section related to operation at maximum differential pressure modified Section 5.4: Reference made to lifting lug requirements for all parts subject to assembly / disassembly

Specification for the Technical Supply of Valves Revision: P4-0

Rev.

Status: IAA

REVISION DESCRIPTION

WRP-SPC-MTE-GEN-027

Date: 25 June 2015

DATE ISSUED

Page 3 of 64

UPDATE / AMENDMENT DETAILS Section 5.4.1: Reference added to the number of turns required to operate gear operated valves Section 5.5.2: Note added regarding requirements for stem extension casing Section 5.6: Reference made to preferred seat materials for PMSS seated valves Section 5.7: Seal types defined and o-ring size requirements included Sections 5.9, 5.10, 8.10 & 8.11: Reference to Specification for the Technical Supply of Bolts & Gaskets, WRP-SPC-MTE-GEN-031 added Section 5.11: Note included that valve VENDOR shall provide detailed valve drawings to the selected interlock VENDOR Section 5.12: Weight limit reduced to 25 kg Section 5.13.1: Note added stating that all valve body vent / drain connections shall be perpendicular to the valve body Section 5.13.2: Ball valve vent & drain connection table updated Section 5.13.4: Termination level of ancillary valve connections included Section 6.2: Requirements for valve dimensions of buttweld end ball valves included Section 6.4: Reference made to Seismic Design Criteria, WRP-SPC-STR-GEN-005 and additional design criteria provided Section 6.7: Requirements for flow direction arrows for DIB-2 ball valves incorporated Section 6.8: Note added, stating that the requirements for spare parts to be included as an option by the VENDOR Section 7.2.1: Reduced bore size reduction specified for large diameter ball valves. Requirements for the use of cast balls included Section 7.2.6: Plug valve pattern type requirements defined and requirements for design of buried plug valves specified

Specification for the Technical Supply of Valves Revision: P4-0

Rev.

Status: IAA

REVISION DESCRIPTION

WRP-SPC-MTE-GEN-027

Date: 25 June 2015

DATE ISSUED

Page 4 of 64

UPDATE / AMENDMENT DETAILS Section 8: Additional reference added to the PED compliance requirement for valve materials Section 9.2: Requirements for the approval of fully welded valve body designs included Section 9.4.1: Note added stating that weld repair of forgings is prohibited Section 11.1: Definition of valve operating cycle included. Note included that cavity test shall only be applicable for valves in liquid service Section 11.3:Table of valve testing specifications included Section 11.4: End connection requirements for valve pressure testing specified Section 11.7: Reference made to VENDOR Nitrogen / Helium gas leak test procedure Section 12.1: Reference made to WRP-PCD-QAC-GEN002 for certification requirements for valves. Sections 12.1, 12.3.1 & 12.3.2: Valve serial number added to marking and tagging requirements Section 12.3.2: Valve nameplate requirements included for buried valves Section 14.1: Paint specification references updated for above ground and buried valves

P4-0

IAAP

23-Jun-15

Issued as Approved for Purchase General: The term SUPPLIER has been replaced by VENDOR Section 3.3: Requirement for ‘Certificate of Conformity’ corrected to state ‘Declaration of Conformity’. Section 3.3: PED conformity module updated to include Module H1 for valves ≥ NPS 30 with a fully welded body design and extended stem for below ground installation. Section 5.3.1: Reference to ring joint flange facings removed and replaced with raised face. Section 5.7: Definition of requirements for vacuum service design updated to state that utility service valves are excluded from this requirement.

Specification for the Technical Supply of Valves Revision: P4-0

Rev.

Status: IAA

REVISION DESCRIPTION

WRP-SPC-MTE-GEN-027

Date: 25 June 2015

DATE ISSUED

Page 5 of 64

UPDATE / AMENDMENT DETAILS Section 5.13.2: Definition of vent and drain valves in relation to parent valve modified. Section 8.2.1: Impact testing requirements included for ITCS valve body materials

HOLDS

No.

Section

Description

Input From

Planned Date

Specification for the Technical Supply of Valves Revision: P4-0

Status: IAA

Date: 25 June 2015

WRP-SPC-MTE-GEN-027 Page 6 of 64

CONTENTS 1. 

INTRODUCTION...............................................................................................................11  1.1 

Purpose .............................................................................................................................11 

1.2 

Exclusions .........................................................................................................................11 

2. 

DEFINITIONS AND ABBREVIATIONS ...........................................................................12  2.1 

General Definitions ...........................................................................................................12 

2.2 

Abbreviations ....................................................................................................................13 

3. 

CODES AND STANDARDS .............................................................................................16  3.1 

Order of Precedence .........................................................................................................16 

3.2 

International Codes and Standards ..................................................................................16 

3.3 

EU Directives ....................................................................................................................18 

3.4 

References ........................................................................................................................19  3.4.1 

4. 

Project Documents ...............................................................................................19 

GENERAL TECHNICAL REQUIREMENTS ....................................................................20  4.1 

Deviations, Concessions and Change Control .................................................................20 

4.2 

Vendor Responsibilities ....................................................................................................20 

4.3 

Health and Safety .............................................................................................................20 

4.4 

Units ..................................................................................................................................20 

4.5 

Design Life ........................................................................................................................20 

4.6 

Language ..........................................................................................................................20 

5. 

VALVE CONSTRUCTION REQUIREMENTS ..................................................................21  5.1 

Body ..................................................................................................................................21 

5.2 

Stems and Glands ............................................................................................................21 

5.3 

End Connections ...............................................................................................................22  5.3.1 

Flanged Ends .......................................................................................................22 

5.3.2 

Socket Weld Ends ................................................................................................22 

5.3.3 

Threaded Ends .....................................................................................................22 

5.3.4 

Buttweld Ends ......................................................................................................22 

5.3.5 

Wafer Type Valves ...............................................................................................23 

5.3.6 

Flange Drilling ......................................................................................................23 

Specification for the Technical Supply of Valves Revision: P4-0

5.4 

5.5 

Status: IAA

Date: 25 June 2015

WRP-SPC-MTE-GEN-027 Page 7 of 64

Operators ..........................................................................................................................23  5.4.1 

Gear Operators ....................................................................................................25 

5.4.2 

Position Indicators ................................................................................................25 

Extended Bonnets/Stems .................................................................................................25  5.5.1 

Extended Bonnets ................................................................................................25 

5.5.2 

Extended Stems ...................................................................................................26 

5.6 

Seats and Back Seats.......................................................................................................26 

5.7 

Soft Seats and Seals ........................................................................................................26 

5.8 

Gland Packing ...................................................................................................................27 

5.9 

Body / Bonnet Gaskets .....................................................................................................27 

5.10 

Bolting ...........................................................................................................................28 

5.11 

Locked and Interlocked Valves ....................................................................................28 

5.12 

Lifting Lugs ...................................................................................................................28 

5.13 

Ancillary Valve Connections .........................................................................................29  5.13.1  General.................................................................................................................29  5.13.2  Vents and Drains..................................................................................................29  5.13.3  Sealant Injection ...................................................................................................30  5.13.4  Ancillary Piping .....................................................................................................30 

5.14 

Bypass Connections .....................................................................................................31 

5.15 

Valve Bearings .............................................................................................................31 

6. 

GENERAL DESIGN REQUIREMENTS ...........................................................................32  6.1 

Pressure Sealing of Block Valves .....................................................................................32 

6.2 

Valve Dimensions .............................................................................................................32 

6.3 

Fire Tested Designs ..........................................................................................................32 

6.4 

Seismic Design .................................................................................................................33  6.4.1 

Buried Valve Design Parameters .........................................................................33 

6.5 

Low Temperature Design..................................................................................................33 

6.6 

Valve Rating ......................................................................................................................33 

6.7 

Flow Direction ...................................................................................................................34 

6.8 

Spare Parts .......................................................................................................................34 

7. 

VALVE DESIGN ...............................................................................................................35  7.1 

General .............................................................................................................................35 

Specification for the Technical Supply of Valves Revision: P4-0

7.2 

8. 

Status: IAA

Date: 25 June 2015

WRP-SPC-MTE-GEN-027 Page 8 of 64

Valve Types ......................................................................................................................35  7.2.1 

Ball Valves............................................................................................................35 

7.2.2 

Gate Valves ..........................................................................................................36 

7.2.3 

Globe Valves ........................................................................................................37 

7.2.4 

Check Valves .......................................................................................................37 

7.2.5 

Modular Double Block & Bleed (DBB) Valves......................................................38 

7.2.6 

Plug Valves ..........................................................................................................38 

7.2.7 

High Performance Butterfly Valves ......................................................................39 

MATERIALS .....................................................................................................................40  8.1 

General .............................................................................................................................40 

8.2 

Impact Tested Carbon Steel (ITCS) .................................................................................40  8.2.1 

Impact Testing ......................................................................................................41 

8.3 

Austenitic Stainless Steel..................................................................................................41 

8.4 

Titanium ............................................................................................................................42 

8.5 

Ductile Iron ........................................................................................................................42 

8.6 

Seat Materials ...................................................................................................................42 

8.7 

Fusion Bonded Epoxy (FBE) Coating ...............................................................................42 

8.8 

Hard Face Coatings ..........................................................................................................42 

8.9 

8.8.1 

Stellite Overlay .....................................................................................................42 

8.8.2 

Tungsten Carbide Coating ...................................................................................43 

8.8.3 

Electroless Nickel Plating (ENP) Overlay ............................................................43 

Alloy 625 Overlay ..............................................................................................................43 

8.10 

Bolting Materials ...........................................................................................................43 

8.11 

Gasket Materials...........................................................................................................43 

8.12 

Stem / Gland Packing ...................................................................................................44 

8.13 

Springs .........................................................................................................................44 

9. 

WELDING, WELD OVERLAY, AND WELD REPAIRS ...................................................45  9.1 

General .............................................................................................................................45 

9.2 

Fully Welded Valve Design ...............................................................................................45 

9.3 

Weld Overlay.....................................................................................................................46 

9.4 

Weld Repairs.....................................................................................................................46  9.4.1 

General Requirements .........................................................................................46 

Specification for the Technical Supply of Valves Revision: P4-0

Status: IAA

Date: 25 June 2015

WRP-SPC-MTE-GEN-027 Page 9 of 64

9.5 

Non-Destructive Examination of Welds ............................................................................47 

9.6 

Charpy V-Notch Impact Testing of Welds .........................................................................47 

10. 

MATERIAL NON DESTRUCTIVE EXAMINATION (NDE)...............................................48 

10.1 

General .........................................................................................................................48 

10.2 

Inspection Lots .............................................................................................................48  10.2.1  Lot Acceptance Criteria ........................................................................................48 

10.3 

Visual Inspection ..........................................................................................................52 

10.4 

Radiography .................................................................................................................52 

10.5 

Ultrasonic Examination (UT) ........................................................................................52 

10.6 

Magnetic Particle Inspection (MPI)...............................................................................53 

10.7 

Dye Penetrant Inspection (DPI)....................................................................................53 

10.8 

NDE Qualifications .......................................................................................................53 

10.9 

Surface Defects ............................................................................................................53 

11. 

VALVE INSPECTION & TESTING ...................................................................................54 

11.1 

Procedure .....................................................................................................................54 

11.2 

Test Water Requirements ............................................................................................54 

11.3 

Testing Standards ........................................................................................................55 

11.4 

84BShell Test......................................................................................................................55 

11.5 

85BSeat Tightness Testing .................................................................................................56  11.5.1  126BTest Direction .......................................................................................................56  11.5.2  127BSeat Leakage .......................................................................................................56  11.5.3  128BHigh Pressure Hydrostatic Testing ......................................................................56  11.5.4  129BLow Pressure Pneumatic Testing ........................................................................57  11.5.5  Backseat Testing..................................................................................................57 

11.6 

86BDisk Strength Test ........................................................................................................57 

11.7 

87BNitrogen / Helium Gas Leak Test for Valves ................................................................57 

11.8 

8BTorque Test ..................................................................................................................58 

11.9 

89BLow Temperature Type Testing of Valves ...................................................................59 

12. 

1BMATERIAL IDENTIFICATION..........................................................................................60 

12.1 

90BCertification...................................................................................................................60 

12.2 

91BTraceability ...................................................................................................................61 

12.3 

92BMarking .........................................................................................................................61 

Specification for the Technical Supply of Valves Revision: P4-0

Status: IAA

Date: 25 June 2015

WRP-SPC-MTE-GEN-027 Page 10 of 64

12.3.1  130BBody Marking .......................................................................................................61  12.3.2  13BNameplates ..........................................................................................................62  12.4 

93BPositive Material Identification (PMI) ............................................................................63 

13. 

12BQUALITY ASSURANCE ..................................................................................................64 

14. 

13BPREPARATION FOR SHIPMENT....................................................................................65 

14.1 

94BPainting .........................................................................................................................65 

14.2 

95BProtection .....................................................................................................................65 

14.3 

96BPreparation for Dispatch ...............................................................................................66 

14.4 

97BHandling and Storage ...................................................................................................66 

APPENDICES APPENDIX A - 

LOW TEMPERATURE TESTING OF VALVES 

Specification for the Technical Supply of Valves Revision: P4-0

Status: IAA

1.

INTRODUCTION

1.1

Purpose

Date: 25 June 2015

WRP-SPC-MTE-GEN-027 Page 11 of 64

The purpose of this specification is to define the minimum technical requirements for the manufacture, inspection, testing and supply of Manual Valves. Manual valves are to be procured using commodity codes and valve purchasing descriptions provided in the Piping Material Line Class specification, WRP-SPC-MTE-GEN-033, supplemented by the requirements specified herein. This specification consolidates additional requirements and restrictions for the VENDOR when procuring manual valves, as per the specified in the Valve Purchasing Description given in the Purchase Order (PO) and / or Requisition. Any reference to VENDOR defines the requirements to be imposed on the VENDOR by the CLIENT/EPCM. The Pressure Equipment Directive (PED) 97/23/EC applies to the TANAP project and all valves shall be supplied in accordance with the requirements of this directive.

1.2

Exclusions This document does not include:  Mainline Pipeline Valves  Instrument Isolation Valves  Instrument Control Valves  Relief Valves (PSVs, TSVs, etc.) Valve body requirements for On-Off Actuated Valves are described in the Specification for the Technical Supply of Motor Operated Valves, WRP-SPC-MTE-GEN-032.

Specification for the Technical Supply of Valves Revision: P4-0

Status: IAA

Date: 25 June 2015

2.

DEFINITIONS AND ABBREVIATIONS

2.1

General Definitions

WRP-SPC-MTE-GEN-027 Page 12 of 64

CLIENT

TANAP DOĞALGAZ İLETİM A.Ş.

PROJECT

Trans Anatolian Natural Gas Pipeline Project.

EPCM

WorleyParsons Proje Yönetimi ve Mühendislik Limited Sirketi

WORK

Shall mean all and any of the WORKs and / or services and / or materials required to be provided by the EPCM under the Contract with CLIENT.

SHALL AND MUST

Indicates mandatory requirements for the purpose of this document.

SHOULD

Indicates that a provision is not mandatory, but recommended as good practice.

Additional definitions specific to this document include: PURCHASER

The party that procures the goods, materials equipment or services

VENDOR

Shall mean any firm or business entering into a CONTRACT with CLIENT to manufacture or supply materials, equipment or plant for incorporation in the permanent works.

SUB-VENDOR

Shall mean any business which is in agreement with VENDOR to manufacture or supply materials, equipment or plant for incorporation in the permanent works

INSPECTION AUTHORITY

Shall mean the inspection bodies which work under the supervision of the CLIENT or EPCM

Specification for the Technical Supply of Valves Revision: P4-0

2.2

Status: IAA

WRP-SPC-MTE-GEN-027

Date: 25 June 2015

Page 13 of 64

Abbreviations Abbreviation

Definition

ANSI

American National Standards Institute

API

American Petroleum Institute

ASME

American Society of Mechanical Engineers

ASNT

American Society of Non-Destructive Testing

ASTM

American Society for Testing and Materials

barg

Gauge Pressure in bar

BB

Bolted Bonnet

BS

British Standard

BSI

British Standards Institute

C

Carbon

cc

Cubic Centimetres

CE

Carbon Equivalent

CL

ASME Class Pressure Rating

cm

Centimetre

Cr

Chromium

CRA

Corrosion Resistant Alloy

CS

Carbon Steel

CTOD

Crack Tip Opening Displacement

Cu

Copper

CV

Valve Flow Coefficient

DBB

Double Block and Bleed (as per API-6D Description)

DIB

Double Isolation and Bleed (as per API-6D Description)

DN

Nominal Diameter in mm

DNV

Det Norske Veritas

DPE

Double Piston Effect

DPI

Dye Penetrant Inspection

ECA

Engineering Critical Assessment

EN

European Norm (European Committee for Standardisation)

ENP

Electroless Nickel Plating

Specification for the Technical Supply of Valves Revision: P4-0

Status: IAA

WRP-SPC-MTE-GEN-027

Date: 25 June 2015

Page 14 of 64

Abbreviation

Definition

EPCM

Engineering Procurement and Construction Management

EXT

Extended

FB

Full Bore

FBE

Fusion Bonded Epoxy

FEA

Finite Element Analysis

FV

Full Vacuum

g

Peak Ground Acceleration

HB

Hardness Brinell

HVOF

High Velocity Oxygen Fuel

ISO

International Organisation for Standardisation

ITCS

Impact Tested Carbon Steel

kg

kilogram

kJ

Kilojoule

µm

Micrometre

mm

Millimetre

Mn

Manganese

Mo

Molybdenum

MPI

Magnetic Particle Inspection

MSS

Manufacturers Standardization Society

N

Newton

NDE

Non Destructive Examination

NFPA

National Fire Protection Association

Ni

Nickel

Nm

Newton Metres

NPS

Nominal Pipe Size (in Inches)

NTP-F

National Pipe Thread - Female

OS&Y

Outside Screw and Yoke

Pa

Pascal

PCB

Polychlorinated Biphenyl

PCTFE

Polychlorotrifluoroethylene

PED

Pressure Equipment Directive

Specification for the Technical Supply of Valves Revision: P4-0

Status: IAA

Date: 25 June 2015

Abbreviation

Definition

PEEK

Polyether Ether Ketone

PO

Purchase Order

ppm

Parts per Million

PQR

Procedure Qualification Records

PSV

Pressure Safety Valve

PTFE

Polytetrafluoroethylene

PWHT

Post Weld Heat Treatment

QA

Quality Assurance

QMS

Quality Management System

Ra

Relative Surface Roughness

RB

Reduced Bore

RF

Raised Face

RTJ

Ring Type Joint

Scf

Standard Cubic Feet

SI

International System of Units

SP

Special Piping Item

TAT

Type Acceptance Test

TEMP

Temperature

TSO

Tight Shut Off

TSV

Temperature Safety Valve

UT

Ultrasonic Examination

VOC

Volatile Organic Compound

WC

Tungsten Carbide

WPQR

Weld Procedure Qualification Record

WPS

Weld Procedure Specification

WRP-SPC-MTE-GEN-027 Page 15 of 64

Specification for the Technical Supply of Valves Revision: P4-0

Status: IAA

Date: 25 June 2015

3.

CODES AND STANDARDS

3.1

Order of Precedence

WRP-SPC-MTE-GEN-027 Page 16 of 64

The following Order of precedence shall be applied to the design codes and standards referenced in this specification:

3.2

1.

Turkish / EU Statutory Legislation & Directives

2.

PO / Requisition Documentation

3.

Project Specifications and Documentation

4.

International Codes & Standards

5.

Industry Standards

6.

Other Referenced Documentation

International Codes and Standards Document Number

Title

API 6D

Pipeline Valves

API 6FA

Specification for Fire Test for Valves

API 594

Check Valves: Flanged, Lug, Wafer, and Butt-welding

API 598

Valve Inspection and Testing

API 599

Metal Plug Valves- Flanged, Threaded and Welding Ends

API 600

Steel Gate Valves- Flanged and Butt-welding Ends

API 602

Steel Gate, Globe, and Check Valves for Sizes NPS 4 (DN 100) and Smaller for the Petroleum and Natural Gas Industries

API 607

Fire Test for Soft Seated Ball Valves

API 609

Butterfly Valves: Double-flanged, Lug- and Wafer-type

ASME B1.20.1

Pipe Threads (General Purpose)

ASME B16.5

Steel Pipe Flanges and Flanged Fittings

ASME B16.10

Face-to-Face and End-to-End Dimensions of Valves

ASME B16.11

Forged Steel Fittings, Socket-Welding and Threaded

ASME B16.20

Metallic Gaskets

ASME B16.25

Buttwelding Ends

ASME B16.34

Valves – Flanged, Threaded and Welding Ends

ASME B16.47

Large Diameter Steel Flanges

Specification for the Technical Supply of Valves Revision: P4-0

Status: IAA

WRP-SPC-MTE-GEN-027

Date: 25 June 2015

Page 17 of 64

Document Number

Title

ASME B18.2.1

Square & Hex Bolts & Screws

ASME B18.2.2

Square & Hex Nuts

ASME B46.1

Surface Texture (Surface Roughness, Waviness and Lay)

ASME V

Non-destructive Examination

ASME VIII

Boiler & Pressure Vessel Code

ASME IX

Qualification Standard for Welding and Brazing Procedures, Welders, Brazers and Welding and Brazing Operators Welding and Brazing Qualifications

ASTM A370

Standard Test Methods and Definitions for Mechanical Testing of Steel Products

ASTM A388

Standard Practice for Ultrasonic Examination of Steel Forgings

ASTM A488

Standard Practice for Steel Castings, Welding, Qualifications of Procedures and Personnel

ASTM A609

Standard Practice for Castings, Carbon, Low-Alloy, and Martensitic Stainless Steel, Ultrasonic Examination

ASTM A751

Standard Test Methods, Practices, and Terminology for Chemical Analysis of Steel Products

ASTM E165

Standard Practice for Liquid Penetrant Examination for General Industry

ASTM E709

Standard Guide for Magnetic Particle Testing

BS 1133

Packaging Code

BS 1868

Specification for Steel check valves (flanged and butt-welding ends) for the petroleum, petrochemical and allied industries

BS 1873

Specification for Steel Globe and Globe Stop and Check Valves (Flanged and Butt-Welding Ends) for the Petroleum, Petrochemical and Allied Industries

BS 6364

Valves for Cryogenic Service

EN 462

Non-Destructive Testing

EN 558-2

Face to Face Dimensions of Valves Class Designated Valves

EN 10204

Metallic products Types of inspection documents

EN 12266-1

Industrial valves - Testing of metallic valves Part 1: Pressure tests, test procedures and acceptance criteria - Mandatory requirements

EN 12266-2

Industrial valves - Testing of metallic valves Part 2: Tests, test procedures and acceptance criteria - Supplementary requirements

EN ISO 10434

Bolted bonnet steel gate valves for the petroleum, petrochemical and allied industries

EN ISO 10497

Testing of valves - Fire type-testing requirements

Specification for the Technical Supply of Valves Revision: P4-0

Status: IAA

Date: 25 June 2015

WRP-SPC-MTE-GEN-027 Page 18 of 64

Document Number

Title

EN ISO 15761

Steel gate, globe and check valves for sizes DN 100 and smaller, for the petroleum and natural gas industries

EN ISO 17292

Metal Ball Valves for Petroleum, Petrochemical and Allied Industries

EEMUA 182

Specification for Integral Block and Bleed Valve Manifolds for Direct Connection to Pipework

ISO 5208

Industrial valves - Pressure testing of metallic valves

ISO 14313

Petroleum and Natural Gas Industries – Pipeline Transportation Systems – Pipeline Valves

MSS SP-9

Spot Facing for Bronze, Iron and Steel Flanges

MSS SP-25

Standard Marking System for Valves, Fittings, Flanges, and Unions

MSS SP-45

Bypass and Drain Connections

MSS SP-55

Quality Standard for Steel Castings for Valves, Flanges and Fittings and Other Piping Components —Visual Method for Evaluation of Surface Irregularities Standard for the Installation of Private Fire Service Mains and their Appurtenances

NFPA 24 97/23/EC

Pressure Equipment Directive

The revision of the above Codes and Standards shall be the current edition at the effective date of agreement. SUPPLER shall advise CLIENT/EPCM of any changes to Codes and Standards after the effective date. VENDOR shall comply with CLIENT/EPCM instruction to comply with any changed Codes and Standards. VENDOR shall advise of conflict among any referenced Codes and Standards and technical specification, and CLIENT/EPCM will determine which shall govern.

3.3

EU Directives All valves shall be compliant with the requirements of 97/23/EC, Pressure Equipment Directive, bear a ‘CE’ mark and be provided with a Declaration of Conformity verifying compliance with conformity module ‘H’ of the Pressure Equipment Directive (PED) 97/23/EC. In addition to the above, valves ≥ NPS 30 with a fully welded body design and extended stem for below ground installation shall be supplied with module H1 and a Certificate of Conformity.

Specification for the Technical Supply of Valves Revision: P4-0

Status: IAA

3.4

References

3.4.1

Project Documents

WRP-SPC-MTE-GEN-027

Date: 25 June 2015

Page 19 of 64

Document Number

Title

WRP-LST-MTE-GEN-002

Piping Material Line Class Index

WRP-PCD-QAC-GEN-002

Quality, Inspection & Surveillance Requirements – Contractors & Subcontractors

WRP-SPC-MTE-GEN-001

Paint Specification

WRP-SPC-MTE-GEN-017

Specification for the Welding, Inspection & PWHT for Plant Piping

WRP-SPC-MTE-GEN-026

Specification for the Technical Supply of Pipe, Fittings & Flanges

WRP-SPC-MTE-GEN-030

Specification for Piping Fabrication & Installation

WRP-SPC-MTE-GEN-031

Specification for the Technical Supply of Bolts & Gaskets

WRP-SPC-MTE-GEN-032

Technical Supply of Motor Operated Valves

WRP-SPC-MTE-GEN-033

Piping Material Line Class Specification

WRP-SPC-MTE-GEN-035

Specification for Positive Material Identification

WRP-SPC-MTE-PLG-011

Specification for Protective Coatings (Paint) for In-Plant Buried Piping & Mainline Pipeline Appurtenances

WRP-SPC-STR-GEN-005

Seismic Design Criteria

Specification for the Technical Supply of Valves Revision: P4-0

Status: IAA

WRP-SPC-MTE-GEN-027

Date: 25 June 2015

4.

GENERAL TECHNICAL REQUIREMENTS

4.1

Deviations, Concessions and Change Control

Page 20 of 64

VENDORs shall refer to the PO for the procedure for raising deviations or concession requests to the technical content of this specification or the Requisition Description. CLIENT/EPCM will consider all deviations and concession requests and approval may be grated at the discretion of the CLIENT/EPCM. No deviation or concession shall be implemented prior to approval being granted. Any deviations or concession implemented prior to approval shall be subject to rejection.

4.2

Vendor Responsibilities It is the responsibility of the VENDOR to ensure that all valves offered are in accordance with all the requirements of this specification and the component description and Valve Purchasing Description given in the PO and / or Requisition.

4.3

Health and Safety The VENDOR shall ensure that no raw materials, components, consumables or processes involved in the manufacture or fabrication of piping components defined within this specification are hazardous to the health and safety of the manufacturing personnel. It is prohibited to use any manufacturing process, materials or substances that could constitute a safety, toxic, microbiological or sensitising hazard or that contain known carcinogens, heavy metals (such as lead or calcium), PCBs, ozone depleting chemicals or VOCs in excess of statutory or local regulations.

4.4

Units In general, the SI system of metric units will be used for the project. Valve nominal diameters shall be stated as nominal pipe size (NPS) in inches.

4.5

Design Life All valves shall be designed to meet a minimum design life of 25 years.

4.6

Language All documentation will be in the English Language.

Specification for the Technical Supply of Valves Revision: P4-0

Status: IAA

Date: 25 June 2015

5.

VALVE CONSTRUCTION REQUIREMENTS

5.1

Body

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The valve body, bonnet and end connections shall be constructed from a forging or casting as per the Valve Purchase Description. The minimum thickness of valve bodies and other pressure containing parts shall be in accordance with ASME B16.34 and ASME VIII Div. 1. Forgings shall be forged as close as possible to their final shape. The valve body shall be designed to withstand a compressive axial thrust without causing detrimental distortion of the valve body, affect the free movement of the closure member or affect the sealing between the seats and closure member. Screwed connections for body to bonnet and body to end connections are not permitted. Unless otherwise specified, short pattern valves are not acceptable. Valve bodies constructed from impact tested carbon steel (ITCS) materials shall be of sufficient thickness to allow for a minimum of 3 mm corrosion allowance in addition to the ASME B16.34 minimum required wall thickness. Where a 6 mm corrosion allowance is specified in the Valve Purchase Description, the valve body wall thickness shall include 6 mm in addition to the ASME B16.34 minimum required wall thickness required for pressure containment purposes. If this corrosion allowance is not achievable, then the VENDOR shall state this within their bid along with recommended alternatives.

5.2

Stems and Glands All valves shall be provided with a one piece, blowout proof stem design, with the stem and body design capable of withstanding the full internal pressure of the valve. Stem retention shall not depend on the packing gland. Glands shall be adjustable and shall have a shoulder on its outer end to prevent complete entry into the stuffing box. The stem and its connection to the closure mechanism must be sufficiently designed to withstand the maximum operating torque at the highest possible pressure differential. Stems shall be capable of withstanding the maximum operating torque applied from the operator at the maximum pressure differential. The weakest point of the stem shall always be outside the valve body and the anti-blow-out mechanism shall not be compromised if the stem was to break at this weak point. The stem shall be permanently and clearly marked to indicate the open / closed position of the valve when the operating mechanism or actuator is removed.

Specification for the Technical Supply of Valves Revision: P4-0

Status: IAA

Date: 25 June 2015

WRP-SPC-MTE-GEN-027 Page 22 of 64

A screwed connection between the stem and the closure mechanism is not permitted.

5.3

End Connections

5.3.1

Flanged Ends All flanged ends must be integral to the valve body. Screwed-in or welded-on flanged end connections are prohibited. Flanges ≤ NPS 24 shall conform dimensionally to ASME B16.5. Flanges ≥ NPS 26 shall conform dimensionally to ASME B16.47 Series A. Flange facings for all ratings shall be raised face (RF). The gasket contact surface finish for raised face and flat faced flanges shall be a continuous spiral groove machined by a round-nosed tool in accordance with ASME B16.5. When gasket contact surface finish is compared by visual or tactile means with appropriate roughness comparison specimens, the surface shall conform to roughness values shown in accordance with ASME B46.1. All jointing faces of non-ferrous flat faced valves shall be machine finished according to ASME B16.5. Flanges shall be cast or forged integrally with the valve body. Flanges attached by welding are not acceptable, without prior agreement and approval, of the relevant Weld Procedure Specification (WPS) and Weld Procedure Qualification Record (WPQR) by the CLIENT/EPCM. In certain valve designs, particularly some butterfly and check valve types; the gasket contact area between the valve and the connecting flange is interrupted by holes for counter bored or countersunk screws used to retain seat rings in the valve. Any such valves shall be identified by the VENDOR in their bid. The joint shall be suitable for the type of gasket specified and the service conditions.

5.3.2

Socket Weld Ends Where specified, valves with socket weld ends shall be in accordance with the VENDOR’s standard, with end connections in accordance with ASME B16.11.

5.3.3

Threaded Ends Where specified, valves with screwed ends shall be in accordance with the VENDOR’s standard. Ends of threaded valves shall be tapped in accordance with ASME B1.20.1 and B16.11. Threaded end valves shall not be used in hydrocarbon service.

5.3.4

Buttweld Ends All buttweld valves shall have their ends bored to suit the pipe wall thickness stated in the Valve Purchasing Description and be prepared in accordance with ASME B16.34 and ASME B16.25, Figures 2a or 3a as applicable.

Specification for the Technical Supply of Valves Revision: P4-0

Status: IAA

Date: 25 June 2015

WRP-SPC-MTE-GEN-027 Page 23 of 64

Where applicable, the Valve Purchasing Description will specify the pup piece material and wall thickness. Valves ≤ NPS 12 shall be supplied with 200 mm pup pieces on each buttweld end and valves ≥ NPS 14 shall have 500 mm pup pieces. The VENDOR shall be responsible for the supply, welding and testing of pup pieces to be connected to buttweld end valves. No pup-piece materials will be free-issued. All pup piece materials shall be supplied in accordance with the Specification for the Technical Supply of Pipe, Fittings and Flanges, WRP-SPC-MTE-GEN-026. The VENDOR shall advise in their bid whether transition pieces are required for buttweld end valves for connecting the pup pieces to the valve body, and shall supply a drawing showing the end to end dimensions of the valve. The VENDOR shall be responsible for confirming that the length of pup-pieces is sufficient that all subsequent welding operations will not have a detrimental effect on any of the valve’s nonmetallic components. All production buttwelds and qualification welds made by the VENDOR for joints between the valve body, transition pieces and pup pieces shall be subject to 100 % radiographic inspection, in accordance with the requirements of the Specification for the Welding, Inspection & PWHT for Plant Piping, WRP-SPC-MTE-GEN-017.

5.3.5

Wafer Type Valves Wafer type valves with exposed bolting are not permitted for use in any hydrocarbon or critical utility service. Where wafer-lugged valves are specified in the Valve Purchasing Description then these valves shall be of the through drilled lug design, such that no bolting inside of the interconnecting flange faces is exposed.

5.3.6

Flange Drilling The flanges of cast iron valves shall be spot faced at the bolt holes in accordance with MSS SP9. The holes shall be equally-spaced about the vertical and horizontal axes of the flange. All end flanges shall be orientated such that the bolt holes straddle the vertical centreline of the valve.

5.4

Operators Valve operation shall be in accordance with the Valve Purchase Description and as indicated in Table 1. All valves shall be capable of opening and closing against the maximum differential pressure (equal to the maximum rated pressure of the valve at 38 ºC for the stated material group in ASME B16.34) that can occur across the valve. The VENDOR shall identify any exceptions to this requirement when submitting their bid.

Specification for the Technical Supply of Valves Revision: P4-0

Status: IAA

WRP-SPC-MTE-GEN-027

Date: 25 June 2015

Page 24 of 64

Consideration should be given to the 'breakout' torque (the torque required to unseat a valve) required to open a valve under maximum differential pressure, to ensure that it is within the maximum forces allowed as stated above. Valves shall be fitted with gearboxes when the break torque exceeds 150 Nm at maximum differential pressure across the valve seat. The maximum force to operate the valve shall not exceed 350 N under maximum differential pressure. The VENDOR shall advise when the time to open or close a manual valve exceeds 5 minutes. Operator types and dimensions shall be stated. If levers are fitted they shall be parallel with the pipeline when the valve is in the open position. Stems with a square top section shall not be acceptable and shall be of an elongated pattern to prevent incorrect orientation. Lever operated valves shall be supplied with the means to padlock the valve in both the open and closed positions. All valve operators shall be permanently marked with ‘Open’ and ‘Closed’ positions with an arrow to indicate the direction of rotation. The fully open position shall be in perfect alignment with the valve body bore. As a general guide, valves in the following sizes shall be gear operated: Valve Type Class Rating

Nominal Pipe Size (NPS) CL150

CL300

CL600

CL900

Gate

≥ 14

≥ 10

≥8

≥8

Globe

≥8

≥8

≥6

≥4

Ball

≥8

≥8

≥6

≥3

Plug

≥6

≥6

≥2

≥2

Butterfly

≥8

≥8

≥6

≥6

Table 1 – Gear Operated Valve Sizes Valve rotational stops shall be independent of operating levers and shall prevent operation beyond the fully open or fully closed position. For lever operated valves, the length of the lever shall be less than twice the valve’s face to face dimension and should never exceed 450 mm. The opening and closing directions on handwheel operated valves shall be clearly marked. The maximum diameter for handwheel operated valves shall be 750 mm. Chain operated mechanisms are not permitted. Valves shall be capable of satisfactory operation with the valve stems in any position i.e. vertical, horizontal or inclined.

Specification for the Technical Supply of Valves Revision: P4-0

Status: IAA

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Date: 25 June 2015

Page 25 of 64

Parts subject to disassembly, e.g. valve/operator interface, shall be identified by the VENDOR in their bid. All separate parts shall be provided with lifting lugs, as per the requirements of Section 5.12 and shall be lubricated on assembly.

5.4.1

Gear Operators Gear operators including lubricants shall be suitable for operation at the ambient temperatures of -40 °C. Where applicable, gear units shall be fully protected from a saline atmosphere, fully enclosed, weather proof, and permit lubrication and maintenance. Bevel type gearing shall be supplied unless specified otherwise in the Valve Purchase Description. Gear operators must be capable of being easily unbolted from the valve body and subsequently be able to be repositioned in 90° increments. Components manufactured from grey cast iron or aluminium alloys are not acceptable. Other grades of cast iron shall be subject to approval by the CLIENT/EPCM. Handwheel material shall be steel, wrought iron, or malleable iron. Pressed steel and aluminium are not acceptable. It shall not be possible for a leaking valve to cause pressurisation of the gearbox. The VENDOR shall include in their bid the number of handwheel turns required to operate the valve from the fully closed to fully open position.

5.4.2

Position Indicators All hand-wheel operated valves shall be fitted with position indicators that cannot be incorrectly orientated, either on initial assembly or during subsequent dismantling and reassembly. Indicators shall be clearly graduated.

5.5

Extended Bonnets/Stems

5.5.1

Extended Bonnets Valves in low temperature service where the minimum design temperature is below -40 °C and where ‘EXTENDED BOLTED BONNET’ is specified in the Valve Purchase Description shall be supplied with an extended bonnet. Valves shall be designed in accordance with BS 6364 and have an outer column with a vapour space between the valve body and the gland seal. The minimum length of vapour space shall be: Valve Size (NPS) Vapour Space (mm)

½–1

1½ - 2

3–4

6–8

10 – 12

14 – 24

200

250

300

350

400

500

Table 2 – Minimum Vapour Space Length in Valve Bonnets

Specification for the Technical Supply of Valves Revision: P4-0

Status: IAA

Date: 25 June 2015

WRP-SPC-MTE-GEN-027 Page 26 of 64

Stems for extended bonnet valves in low temperature or cryogenic services shall be made of one piece only. Welded stems or stems of two or more pieces are not acceptable.

5.5.2

Extended Stems When valves with extended stems are specified for valves in buried service, the length shall be shown within the Purchase Order and /or Requisition. The stem extension shall be fully enclosed and waterproof with a pressure relief system to prevent pressure build-up in the vent of a stem seal failure. For valves buried below ground, the extended stem shall be enclosed in an outer column bolted to the valve body, fully sealed to the valve in order to contain leakage from the stem seal or prevent contamination from in-fill. Where specified, the extension shall accommodate the valve drain, bleed/vent or sealant injection points piped towards the top of the extension to allow for operation and maintenance of the valve from above ground. The stem extension casing shall incorporate a vent located above ground to prevent pressurisation of the Actuator housing (or gear-box, where fitted).

5.6

Seats and Back Seats All valves ≥ NPS 2 shall be furnished with renewable or replaceable seats unless specified otherwise. Integral seats are permitted for valves ≤ NPS 1½. All seats and closures gates, plugs, discs, etc. in carbon steel metal to metal seated valves shall have a minimum hardness of 250 HB with a minimum hardness differential of 50 HB between the seats and obturator. Where ‘PRIMARY METAL/ SECONDARY PEEK SEAT’ is specified in the Valve Purchasing Description for ball valves, this denotes a metal seated valve with a secondary soft seat (PMSS) is required. The recommended material for the secondary soft seat in PMSS seated valves is Polyether Ether Ketone (PEEK) as detailed in the Valve Purchasing Description. Where alternative seat materials are offered, this shall be highlighted in the VENDOR’S bid and subject to CLIENT/EPCM approval. All gate and globe valve designs shall incorporate an integral or permanently affixed stem bonnet backseat, which shall seat a raised face on the stem when the gate / plug is in its fully opened position. The hard-facing requirements for the stem backseat shall match those specified for the body seat.

5.7

Soft Seats and Seals All soft seat and seal materials shall be suitable for the service, minimum/maximum design temperature and design pressure, as stated in the individual Valve Purchase Description Seals shall preferably be self-energised lip seals.

Specification for the Technical Supply of Valves Revision: P4-0

Status: IAA

Date: 25 June 2015

WRP-SPC-MTE-GEN-027 Page 27 of 64

All soft seat and seal materials in hydrocarbon services shall be resistant to explosive decompression. Where o-ring seals are utilised, the cross-sectional diameter shall be less than 6.0mm and the VENDOR shall guarantee their anti-explosive properties. All seat and seal materials in hydrocarbon services shall be suitable for handling Methanol doses for short periods. VENDOR shall state maximum permitted in their bid. The stem sealing system should employ a double seal design with a leak-off valve. Upper stem seals shall be replaceable while the valve is in operation. All valves (including seal and packing design and materials) shall be suitable for operation in Full Vacuum (FV) service with the following exceptions:

5.8



All ductile iron valves



All internally lined valves

Gland Packing Gland packing shall be suitable for the service and conditions shown in the Valve Purchase Description and shall be compatible with the stem material. All graphite or carbon type gland packing shall contain a suitable zinc free corrosion inhibitor. Packing shall be of square section and preferably supplied in pre-formed rings. Boxed spirals or coils may also be used. Packing sections below 6.5 mm may be of round section, preferably supplied in coils. Any lubricated packing for low temperature duties shall not solidify or have any detrimental effect on the valve operation at low temperatures. All gate and globe valves shall be provided with a back-seat or other means of packing the stuffing box while the valve is in service under the maximum rated pressure. The use of lantern rings is not permitted.

5.9

Body / Bonnet Gaskets Gaskets shall be in accordance with Specification for the Technical Supply of Bolts & Gaskets, WRP-SPC-MTE-GEN-031 and be compatible with all valve materials of construction. The body to bonnet connection shall be flanged and the flange facings shall be male-andfemale, tongue-and-groove, or ring type joint, except CL150 which can be flat face. Spiral wound gaskets shall be used on CL300 through CL1500 valves. Metallic ring type joints shall be used on CL900 and higher ratings and all valves in severe service. Spiral wound gaskets shall have an inner ring unless fully contained in a groove.

Specification for the Technical Supply of Valves Revision: P4-0

5.10

Status: IAA

Date: 25 June 2015

WRP-SPC-MTE-GEN-027 Page 28 of 64

Bolting All bolting shall be in accordance with Specification for the Technical Supply of Bolts & Gaskets, WRP-SPC-MTE-GEN-031, shall comply with that specified in the Valve Purchase Description and shall meet the requirements of ASME B16.34 paragraph 6.4. The VENDOR is responsible for the design and application of all bolted joints integral to the valve. The VENDOR shall select the type of fastener, its size and its thread design. However, the material grade shall be in accordance with the valve descriptions stated within the piping classes and the requirements of this specification.

5.11

Locked and Interlocked Valves All valves, excluding check valves, shall have a capability of being locked open or closed using a CLIENT/EPCM supplied heavy duty padlock and valves shall be equipped with suitable robust brackets or other devices necessary to achieve this. Alternatively, small-bore lever operated valves may be equipped with locking plates. All locking facilities shall be approved by the CLIENT/EPCM. Interlocked valves shall be equipped with proprietary locking devices, such that replacement of the hand-wheel / lever is the only modification required on the valve. The VENDOR shall liaise with the selected interlock manufacturer to ensure compatibility of valve and locking device. Locking devices will be fitted to the valves after installation and will not be the responsibility of the valve VENDOR. VENDOR shall provide the interlock manufacturer with all required valve drawings to assist in the design of interlocks for each type of valve.

5.12

Lifting Lugs All valve assemblies, inclusive of operators; with a weight over 25kg shall be provided with adequate integral lifting points to facilitate installation and/or maintenance in both the vertical and horizontal positions. Lifting attachments shall be complete with verified documentation and safety instructions. The safe working load of each lifting joint or attachment shall exceed the weight of the valve and operator assembly. The lugs shall preferably be integral to the body but may also be attached by means of a full penetration weld attached prior to heat treatment. Strength calculations shall be available from the VENDOR and any welding shall be subject to the necessary heat treatment and NDE as described within this specification.

Specification for the Technical Supply of Valves Revision: P4-0

5.13

Status: IAA

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Date: 25 June 2015

Page 29 of 64

Ancillary Valve Connections

5.13.1 General All ancillary connections made to the valve body for vents, drains, bypasses, flushing, sealant injection, etc. shall be designed to and comply with the requirements of MSS SP-45, ASME B16.34 and the details specified herein. All connections shall be integral to the valve body or connected by a full penetration weld. The connections shall not weaken the valve body or limit the pressure containing capabilities. All connections shall be taken off the valve perpendicular (horizontal) to the centreline axis of the valve body. All such ancillary connections and associated piping shall be clearly detailed and dimensioned on the valve detail drawings.

5.13.2 Vents and Drains The drain connection shall be at the lowest possible point on the valve body and the vent shall be at the highest possible point. Valves ≤ NPS 4 may have a combined drain and vent located at the lowest possible point on the valve body. Cavity vent and drain connections shall be in accordance with MSS SP-45 and as described in the following table: Valve Size (NPS)

Class Rating

Extended Stem

Connection Size (NPS)

Closure Description

≤ 1½

≤ CL1500

No

None

N/A

2 ≥ NPS ≤ 4

≤ CL1500

No

½" NPT-F

Bleed Plug

6 ≥ NPS ≤ 8

≤ CL300

No

¾" Flange

Blind Flange

6 ≥ NPS ≤ 8

≥ CL600

No

¾" Flange

DBB & Blind Flange

10 ≥ NPS ≤ 24

≤ CL300

No

1" Flange

Blind Flange

10 ≥ NPS ≤ 24

≥ CL600

No

1" Flange

DBB & Blind Flange

28 ≥ NPS ≤ 56

CL600

No

2" Flange

DBB & Blind Flange

3 ≥ NPS ≤ 24

CL600

Yes

1" BW

DBB & Blind Flange

28 ≥ NPS ≤ 56

CL600

Yes

2" BW

DBB & Blind Flange

Table 3 – Ball Valve Vent & Drain Connections The reference to ‘Extended Stem’ in the above table defines whether the valve is installed above or below ground (directly buried).

Specification for the Technical Supply of Valves Revision: P4-0

Status: IAA

Date: 25 June 2015

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Where threaded connections are permitted, body tappings shall be in NPT taper pipe threads accordance with ASME B1.20.1 and a cross-sectional detail of all ancillary connections shall be shown on the valve drawing. Where threaded connections are applied, then the VENDOR is to ensure that the correct number of threads is engaged as required by ASME B1.20.1. Each threaded connection shall be supplied with a bleed plug, which is a plug equipped with an integral facility to bleed off the pressure contained by the plug whilst the plug is still securely engaged in the valve. The bleed off facility shall be metal seated and of an anti-blow-out design. Flanged connections shall be made using ASME B16.5 / ASME B16.47 weldneck flanges in accordance with Section 5.3.1, which shall be attached to the valve body by means of a full penetration weld in accordance with Section 9. Valve connections shall be isolated with Monoblock (single body design) modular Double Block & Bleed (DBB) type valves supplied in accordance with this specification. The technical description of the modular DBB shall be consistent with the Valve Purchasing Description for the “parent” mainline valve. Where buttweld vent and drain connections are specified for extended stem valves which are to be installed below ground, Section 5.3.4 shall be applied.

5.13.3 Sealant Injection Emergency stem and seat sealant injection shall be included for all trunnion mounted ball valves ≥ NPS 4 with a rating ≥ CL600 allowing for sealant to be injected under full line pressure. All valves in underground service with an extended stem shall also be supplied with stem and seat sealant injection facilities. The design of stem and seat sealant injection connections shall incorporate a double non-return valve arrangement fitted with a plug or pipe cap. All connections to the valve body for the purpose of sealant injection shall be fully welded to the body.

5.13.4 Ancillary Piping In general, isolation of ancillary connections shall be made directly at the valve body without the need for additional piping. However, where the requirement for extended stem is specified in the Valve Purchasing Description, the valve is to be installed below ground (directly buried) and as such, all connections shall be hard piped from the valve body, up the stem extension and terminate at the top of the valve at a level approximately one metre above grade. Details of the required level and orientation of the ancillary connection isolation valves along with the length of the extended stem will be defined in the PO and / or Requisition. The routing of the piping and the location of the termination points shall be such that operation and maintenance of the valve is not impaired. All piping from the connection to the valve body shall be fully buttweld and supported in two planes (to prevent overstressing of joints and vibration induced cracking) back to the valve where required.

Specification for the Technical Supply of Valves Revision: P4-0

Status: IAA

Date: 25 June 2015

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All piping shall be complete and included as part of the valves hydrostatic shell strength test. VENDOR shall ensure that all piping wall thicknesses are adequate for the valve’s hydrostatic test pressure. No additional welding of supports shall be made to the valve body after the pressure testing is complete. The following project documents shall be complied with for the materials and welding of the ancillary piping:

5.14



Specification for Piping Fabrication & Installation, WRP-SPC-MTE-GEN-030



Specification for the Technical Supply of Pipe, Fittings & Flanges, WRP-SPC-MTEGEN-026



Specification for the Technical Supply of Bolts & Gaskets, WRP-SPC-MTE-GEN-031



Specification for the Welding, Inspection and PWHT for Plant Piping WRP-SPC-MTEGEN-017

Bypass Connections Where specified, penetration of the pressure wall of the valve for bypasses shall meet the requirements of ASME B16.34 and MSS SP-45.

5.15

Valve Bearings Valve bearings shall be capable of accommodating the static and dynamic loads in the valve. Design shall take into account the thrusts resulting from the out of balance forces generated in the valve when pressure is applied to only one side of the valve and due to the stem retention force. The bearings shall be of a proven design using dissimilar hardness materials to avoid galling or pick-up.

Specification for the Technical Supply of Valves Revision: P4-0

Status: IAA

Date: 25 June 2015

6.

GENERAL DESIGN REQUIREMENTS

6.1

Pressure Sealing of Block Valves

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Block valves shall be designed to seal in both directions against all pressures up to the maximum service pressure rating as defined in ASME B16.34, unless specified otherwise in the Valve Purchase Description.

6.2

Valve Dimensions Face to face dimensions shall be in accordance with ASME B16.10 or EN 558-2, unless otherwise noted in the Valve Purchase Description. All flanged ball valves shall be long pattern with the corresponding face to face. Plug valves shall be supplied as short pattern for CL150 NPS 1 - 12 and CL300 NPS 1 - 4. All other sizes shall be supplied regular pattern. End to end dimensions of screwed end or socket weld end valves shall be in accordance with the VENDOR’s standard. All dimensions to be included with the VENDOR’s bid. The face to face dimensions of buttweld end ball valves shall be provided by the VENDOR with their bid, and shall be based upon the length of the valve body in accordance with ASME B16.10 and the requirement for transition pieces and the length of pup-pieces as per Section 5.3.4. The VENDOR shall provide assembled weights of the valve and operator within their bid.

6.3

Fire Tested Designs All valves, where required to be fire-safe in accordance with the Valve Purchase Description, shall be of a fire tested design and shall be certified accordingly. Valves shall be fire tested in accordance with EN ISO 10497. The materials of construction of the valve shall not vary from those specified on the Fire Test Certificate. Valves in accordance with the requirements of API-6FA are acceptable provided that the VENDOR can confirm that the measured leakage rates after fire testing meet ISO 10497 requirements. Quarter turn soft seated valves may be fire testing in accordance with API 607 as an alternative to EN ISO 10497 Fire tests shall have been witnessed and certification issued by an independent INSPECTION AUTHORITY e.g. BSI, Lloyds, DNV, etc.

Specification for the Technical Supply of Valves Revision: P4-0

6.4

Status: IAA

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Date: 25 June 2015

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Seismic Design The design of buried valves, specifically the stem design and the design of all components protruding above ground shall be generally in accordance with the requirements of the Seismic Design Criteria, WRP-SPC-STR-GEN-005 and take in account the seismic design data as stated below: X (Axial) 

Y (Vertical) 

Z (Lateral) 

± 2.14 g 

± 0.576 g 

± 0.642 g 

± 0.642 g 

± 1.92 g 

± 0.642 g 

± 0.642 g 

± 0.576 g 

± 2.14 g 

Table 4 – Seismic Design Criteria VENDOR shall advise if any additional information is required to satisfy the design parameters of the valves for installation in areas of seismic activity.

6.4.1

Buried Valve Design Parameters The design parameters for soil loads acting on the valve stem and ancillary piping shall be taken as follows:

6.5



Pipe burial depth = 1.5 m (to top of pipe)



Axial pipe movement at valve = 50 mm Maximum



Soil properties, the most onerous of: i)

Density 2276 kg/m3 , angle of internal friction 40 degrees

ii)

Density 2276 kg/m3, angle of internal friction 32 degrees, cohesion 50 KPa

Low Temperature Design Where ‘LOW TEMP’ is specified within the Valve Purchase Description, the valve will be required to seal and survive the quoted low temperature but will not be required to be operated at this low temperature. If the VENDOR’s offered valve cannot achieve this, then the VENDOR shall advise this with their bid. Where a valve is required to be operated at the quoted low temperature, ‘EXTENDED BOLTED BONNET’ is specified within the Valve Purchase Description and Section 5.5 shall be adhered to.

6.6

Valve Rating Unless otherwise specified in the Valve Purchase Description, all valves shall be fully rated to the ASME pressure class rating as detailed in ASME B16.34.

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A pressure / temperature chart for all soft seat / seal materials shall be provided by the VENDOR in their bid.

6.7

Flow Direction The direction of flow, for uni-directional valves and where applicable, the tight shut-off direction(s), shall be clearly indicated by a permanent mark cast or stamped on the valve body; painted markings are not permitted. Unless otherwise stated on the Valve Purchase Description, the direction of flow for double isolation and bleed (DIB) type 2 ball valves shall be such that the Double Piston Effect (DPE) seat is on the downstream side of the valve. A flow direction arrow shall be integrally cast on the body of all DIB-2 ball valves.

6.8

Spare Parts During the bid phase, the VENDOR shall include as an option within their bid, all spare parts required during commissioning, start-up and for the first two years of operation.

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7.

VALVE DESIGN

7.1

General

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All valves shall be suitable for services and design pressure / temperature conditions stated in the Valve Purchase Description. Valves shall be designed to prevent solids from collecting where they will be detrimental to valve operation e.g. seat pockets, trunnion, etc.

7.2

Valve Types

7.2.1

Ball Valves Ball valves shall have bolted body with end or top entry, or have a fully welded body as specified in the Valve Purchase Description and as described in Section 9.2. Flanged valves shall be supplied as a bolted bonnet, 2 or 3 piece split body design and the end flanges shall be integral to the valve body. One piece body constructions with end entry and screw in or welded in ends are prohibited. The design of floating ball or trunnion mounted ball valves for liquid services shall incorporate body cavity pressure relief. A pressure relief hole in the ball is not permitted for Trunnion Mounted ball valves. Self-relieving seat rings shall relieve the body cavity pressure before it reaches 133 % of the class rating pressure at the upper design temperature. The self-relieving requirement is applicable for the whole valve design temperature range as per appropriate class. Note that for bi-directional trunnion mounted ball valves with self-relieving seat rings, the cavity will relieve to whichever side has the lowest pressure. Ball valve design shall provide for repeatable, positive methods of accurately aligning the bores of the valve body and ball with the valve in line. Accuracy shall be maintainable to 0.25 mm up to NPS 2 and to the lesser of 0.5 mm or 1 degree for sizes > NPS 2. Ball valves shall be provided with anti-static devices that shall be tested in accordance with EN ISO 17292. Where specified in the Valve Purchase Description trunnion mounted ball valves shall be DIB types DIB-1 or DIB-2 as per the descriptions within API 6D / ISO 14313. A DIB-1 type valve shall be taken to mean a single bodied, trunnion mounted ball valve with a single ball and two DPE seating surfaces, each of which, in the closed position, provides a seal against pressure from a single source, with a means of venting / bleeding the cavity between the seating surfaces. A DIB-2 type valve shall be taken to mean a single bodied, trunnion mounted ball valve with a single ball, one DPE seat and another Self Relieving seat, each of which, in the closed position,

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provides a seal against pressure from a single source, with a means of venting / bleeding the cavity between the seating surfaces. All ball valves shall be bi-directional with the exception of valves specified as DIB-2, which are uni-directional, due to the seating arrangement. Full bore ball valves shall be supplied for sizes NPS ½ - 1½. Reduced bore ball valves shall be supplied for sizes ≥ NPS 2 unless otherwise indicated in the Valve Purchase Description. Reduced bore ball valves ≤ NPS 24 shall be limited to one size reduction. For larger sizes the reduction in size shall not exceed 100 mm. Ball valves shall be trunnion mounted design in accordance with the following: Pressure Rating

Size (NPS)

CL150

≥8

CL300

≥6

≥ CL600

≥2

Table 5 – Trunnion Mounted Ball Valves All ball valves shall be furnished as long pattern, unless specified otherwise in the Valve Purchase Description, with the corresponding face to face dimension. For all sizes of valve the ball shall be a solid one piece forged construction. However, the VENDOR shall confirm that for large diameter valves ≥ NPS 30 that a solid ball design does not have a long term detrimental effect on the sealing effect of the valve’s seats. Hollow and split two piece balls are not acceptable. Where a cast ball is proposed by the VENDOR, this shall be clearly identified in their bid and will be subject to acceptance by the CLIENT/EPCM. Weld repair of cast balls is only permitted with the express written permission of the CLIENT/EPCM. Trunnion mounted valves shall have pressure energised seats. The design of the soft seat inserts shall be such that the seat material shall not be displaced or get out-of-shape when under pressure or during de-pressurisation.

7.2.2

Gate Valves Gate valves shall be plain solid wedge gate, flexible solid wedge gate or parallel slide gate. The specific type of gate valve required and the applicable valve design standard will be specified in the Valve Purchase Description. Unless otherwise specified gate valves shall have a one piece body with integral end flanges, bolted bonnet, full port, metal seats, outside screw & yoke (OS&Y), a rising stem and a nonrising operator. Generally, solid wedge gate valves shall be used in sizes NPS ½ to NPS 1½; flexible wedge gate valves shall be used for sizes ≥ NPS 2. Other types of gate valves shall be used in sizes depending on their application.

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Gates in wedge gate valves shall be forged or cast. Welded fabrication is not acceptable. OS&Y valves shall be furnished with screw stem protectors in valve sizes ≥ NPS 3. Gate valves in fire water service shall be provided with post indicators in accordance with the requirements of NFPA 24, where ‘PI’ is specified in the relevant Valve Purchase Descriptions.

7.2.3

Globe Valves Unless otherwise specified globe valves shall have a one piece body with integral end flanges, bolted bonnet, full port, metal seats, outside screw & yoke (OS&Y), a rising stem and a nonrising operator. The specific type of globe valve required and the applicable valve design standard will be specified in the Valve Purchase Description. Globe valves shall be provided with plug type discs. VENDORs shall submit CV values for globe valves with their bid.

7.2.4

Check Valves Check Valves shall be capable of operating in both the vertical and horizontal position unless stated otherwise in the Valve Purchase Description. The specific type of check valve required and the applicable valve design standard will be specified in the Valve Purchase Description. All check valves shall have a flow direction arrow integrally cast into the valve body. Dual Plate Check Valves Dual plate check valves shall be of a retainerless design with spring loaded plates and renewable hard facing seats. Dual plate check valves shall be supplied as lug type or double flanged designs to ensure that bolting is only exposed at the end threads past the nut. The design of the valve should be such that no screwed components or inserts impinge upon the gasket contact surface areas. Swing Check Valves Swing type check valves shall be top entry, bolted bonnet, flanged ends, renewable hard facing seats and long pattern face to face in accordance with ASME B16.10. The body shall be a one piece design with the end flanges integral to the valve body. Swing Check valves shall have a travel stop to limit disc swing in the open position. The body seat ring shall be inclined or the hinge shall be provided with an offset. The disc shall be one piece and the disc nut shall be drilled and pinned.

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Piston Check Valves Piston check valves shall be top entry, bolted bonnet, flanged ends, integral hard facing seats and long pattern face to face in accordance with ASME B16.10. The valve shall have an integral or separate guide of sufficient length to ensure effective guidance over the full length of piston travel. Non-Slam Check Valves Where required, non-slam (axial type) check valves shall be designed as SP-Items. Spring selection and closure response shall be based on the design conditions stated in the Valve Purchase Description or SP-Item data sheet. VENDOR shall submit a cross-sectional and dimensional valve drawing with their bid.

7.2.5

Modular Double Block & Bleed (DBB) Valves Modular DBB valves shall be in accordance with ASME B16.34, EEMUA Publication 182 and the requirements of this specification. Modular DBB valves shall be of the Monoblock (one piece body) design with two ball isolations and an NPS ½ needle valve vent. Face-to-face dimensions shall be in accordance with the VENDOR’s standard. VENDOR shall submit a cross-sectional and dimensional valve drawing with their bid. Care shall be taken in machining tolerances and the torque required in Modular DBB valves with some soft seat materials. Detaching the operator on Modular DBB valves shall not affect the pressure retaining abilities.

7.2.6

Plug Valves Plug valves shall be of the lubricated design with a ‘pressure balanced’ tapered plug type, metal to metal seats and provided with a blow-out proof stem and an anti-static device. Plug valve design shall provide for repeatable, positive methods of accurately aligning the bores of the valve body and plug with the valve in line. Accuracy shall be maintainable to 0.25 mm up to NPS 2 and to the lesser of 0.5 mm or 1° for sizes ≥ NPS 2. Plug valves shall be supplied as ‘regular pattern’ design for all sizes in classes rated ≤ CL300. For plug valves in piping classes rated ≥ CL600, valves shall be regular pattern for sizes ≤ NPS 12 and ‘venture pattern’ for all larger sizes. The VENDOR shall specify the pattern type offered within their bid. Where a cast plug is employed, weld repair of the plug is only acceptable with prior written approval from the CLIENT/EPCM. For buried plug valves, where fully welded body construction is not possible; the body design shall ensure that ingress of foreign matter into the valve is not possible.

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7.2.7

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High Performance Butterfly Valves All high performance butterfly valves shall be of the triple-offset type, with a double flanged body, bi-directional and designed for tight shut-off. All operators shall be capable of seating, unseating and, in the case of geared operators, holding the valve disc in any intermediate position under all operating conditions. Wrench operators shall be capable of holding the disc in at least 5 equally intermediate positions between fully closed and fully open. Where position indicators are required, they shall be graduated from 1 to 10, fully open to fully closed.

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8.

MATERIALS

8.1

General

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All materials shall be new, clean and free from rust, mill scale, pits and other defects or contamination. All equipment used in the manufacturing process, such as dies, presses, rolls, etc. shall be free from dirt, scale and surface contaminants prior to use. No cast, ductile, grey or malleable irons, plastic or copper alloys shall be used for valves in hydrocarbon service. All materials utilised in valves shall comply with the requirements of PED 97/23/EC.

8.2

Impact Tested Carbon Steel (ITCS) Materials shall be supplied in strict accordance with the applicable ASTM standard specification with the following additional supplementary requirements applied:

Product

Standard

Grade

Class

Supplementary Requirements

Acceptance Criteria

Forgings

ASTM A350

LF2

1

N/A

Section 10

LF6

2

LCC

-

Castings

ASTM A352

Table 6 – ITCS Testing Requirements All carbon steel must be fully killed (de-oxidised) and weldable with minimum pre-heat. Micro-alloying elements such as Vanadium (V), Niobium (Nb), Titanium (Ti) and Boron (B) shall not be added to increase the strength of the materials. All ITCS materials shall be subject to the following composition requirements: 

Carbon (C) ≤ 0.23 %



Manganese (Mn) = 0.50 % - 1.35 %



Sulphur (S) ≤ 0.025 %



Phosphorus (P) ≤ 0.030 %



CE (IIW) = C + (6 x Mn) + Cr + Mo + (5 x V) + Cu + (15 x Ni) ≤ 0.43

Product analysis to confirm the above compositions shall be made for base material, HAZ and weld deposit, as per ASTM A751. Mechanical testing shall be carried out in accordance with the requirements of the particular ASTM standard Specification and, where referenced, ASTM A370.

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Impact Testing All ITCS materials with a thickness ≥ 6mm shall be subject to transverse Charpy V-Notch (CVN) impact testing as per the requirements of the material’s ASTM standard specification, ASTM A370 and ASTM E23. Tests shall be performed on each component type per lot. The impact test temperature shall be the lower of the value specified in the ASTM standard specification and -40oC. The minimum allowable absorbed energy values shall be in accordance with the applicable ASTM standard specification. CVN absorbed energy values for ASME B31.8 pipeline valves shall be identified within the purchase descriptions and shall be 60 Joules minimum average and a 50 Joules minimum individual value for all material grades up to and including a SMYS of 70 ksi. Unless otherwise specified in the purchase description, the minimum acceptable absorbed energy values for ASME B31.3 valves shall be 27 Joules minimum average and a 20 Joules minimum individual value. Values for longitudinal samples shall be 150% of the values specified for transverse samples. Where possible, full size 10.0 x 10.0 mm specimens shall be removed for testing. Where this is not possible, due to component thickness, size or other constraints, then sub-size specimens may be used in accordance with the table below. Specimen Size (mm)

Energy Reduction Factor

10.0 x 7.5

80%

10.0 x 5.0

66%

Table 7 – CVN Specimen Sizes

8.3

Austenitic Stainless Steel All Austenitic stainless steel SS316 materials shall be supplied as Dual Certified, with the mechanical properties of SS316 and the chemical composition of SS316L. The materials shall be specified as SS316/SS316L. All Austenitic stainless steel components shall be furnished in the solution annealed condition, which shall be carried out after all cold work and welding operations. For all products, the carbon content shall be ≤ 0.030 %.

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All stainless steel components, with the exception of machined surfaces shall be supplied white pickled.

8.4

Titanium The requirements for Titanium material shall match the requirements specified in the Valve Purchasing Description and the relevant sections of this specification. Weld repair of Titanium products is not permitted If tensile test properties cannot be achieved in the ‘as formed’ condition, tensile test shall be carried out for each heat, heat treatment load, type and size.

8.5

Ductile Iron Ductile Iron cast materials for gate valve bodies shall be supplied in accordance with ASTM A395, Grade 60-40-18.

8.6

Seat Materials All ball valves in cryogenic service below -40 °C shall be supplied with PCTFE seats. All ball valves supplied with ‘Reinforced’ PTFE seats shall be suitable for a maximum design temperature of 150 °C and the coincidental pressure rating of ASME B16.34 for the specified body material. VENDORs shall submit details of the limitations of seat materials with their bid.

8.7

Fusion Bonded Epoxy (FBE) Coating Where specified in the Valve Purchasing Description for ductile iron valves in water service, an FBE coating shall be bonded the inside of the valve body. The VENDOR shall provide a coating procedure detailing all aspects involved in the coating process, including but not limited to; surface preparation, type of thermosetting resin powder to be used, coating methodology, finished thickness, inspection and testing requirements.

8.8

Hard Face Coatings

8.8.1

Stellite Overlay Where hard seating faces are required for gate, globe and check valves, then the seats and / or plate, disc or wedge, dependent upon the specified API trim specified on the Valve Purchase Descriptions, shall be supplied with an overlay of Stellite grade 6 or 21. The minimum thickness of Stellite applied shall be 1.6 mm. The closure & seat overlays shall have a differential hardness to mitigate the risk of galling.

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8.8.2

Status: IAA

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Tungsten Carbide Coating Where ‘METAL ST’ is specified in the Valve Purchase Description, then the complete surface of the ball and seats shall be tungsten carbide (WC) coated using a HVOF (High Velocity Oxygen Fuel) process. The coating shall be of the cermet type based on tungsten carbide and a metallic binder. The binder shall be based on cobalt alloyed with chromium. Pure cobalt or nickel binders are not acceptable due to the low corrosion resistance. The minimum coating thickness after grinding, polishing and lapping shall be 200 μm with a surface roughness less than or equal to 10 μm. The ball & seat overlay materials shall have a differential hardness to mitigate the risk of galling. The two metallic seats shall be lapped with the hard faced ball to ensure the required seat tightness can be achieved.

8.8.3

Electroless Nickel Plating (ENP) Overlay Electroless Nickel Plating (ENP) is not an acceptable material for corrosion resistance, but may be considered for providing erosion / wear resistance where necessary. Where specified in the Valve Purchase Description ENP shall be in accordance with ASTM B733 Type 2 for coating carbon steel and Austenitic stainless steel components in valves.

8.9

Alloy 625 Overlay For all fully welded bodied ball valves in below ground (directly buried) service and for all ball valves ≥ NPS 30 with a rating ≥ CL600, seat pocket areas shall have an Alloy 625 weld overlay. The overlay thickness shall be sufficient to obtain a minimum of 3 mm after final machining. This shall be identified by the VENDOR on the valve general arrangement drawing.

8.10

Bolting Materials All bolting shall be in accordance with Specification for the Technical Supply of Bolts & Gaskets, WRP-SPC-MTE-GEN-031 and be compatible with all valve materials of construction. The use of cadmium plated bolts is strictly prohibited due to the health risks associated with the plating process.

8.11

Gasket Materials Gaskets shall be in accordance with Specification for the Technical Supply of Bolts & Gaskets, WRP-SPC-MTE-GEN-031 and be compatible with all valve materials of construction. Materials for spiral wound gaskets shall be as follows: Windings:

Austenitic stainless steel AISI 316L

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Filler Material:

Exfoliated expanded graphite (suitable for service fluid and temperature range of the piping material class)

Inner Ring:

Austenitic stainless steel AISI 316L

Outer Ring:

Austenitic stainless steel AISI 316L

Under no circumstances shall asbestos based filler materials be used. Compressed non-asbestos gaskets for bonnet joints shall be graphited both sides except where used with austenitic stainless steel or non-ferrous flanges. Gaskets for use with Austenitic stainless steel materials shall have controlled low chloride content with leachable chlorides less than 200 ppm.

8.12

Stem / Gland Packing Stem sealing shall be in accordance with the VENDOR’s standard design, but should preferably contain diagonal braided carbon yarn, top and bottom anti-extrusion rings and pre-formed compressed intermediate rings of flexible graphite. Under no circumstances shall CAF (compressed asbestos fibre) materials be used.

8.13

Springs Unless otherwise specified in the Valve Purchasing Description, all springs for use in valves (energised seats, lip seals, spring return devices, etc.) shall be made from a suitable Corrosion Resistant Alloy (CRA), such as Inconel X-750 (UNS N07750) or Elgiloy (UNS R30003). Spring materials made from Austenitic stainless steel are not acceptable.

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9.

WELDING, WELD OVERLAY, AND WELD REPAIRS

9.1

General No welding, including repair welds, shall be performed without approved weld procedure specifications (WPS) and weld procedure qualification record (WPQR). The CLIENT/EPCM reserves the right to refuse any weld repair. Where it is necessary to modify a valve or repair a casting by welding, full details of the modification, i.e. weld map, weld procedures, weld procedure qualifications, welder qualification, and NDE, shall be submitted for CLIENT/EPCM approval prior to commencement. All welding procedure specifications shall be qualified in accordance with the requirements of ASME IX and shall be subject to NDE as required in ASME V and this specification. However, procedure qualifications shall be performed on the specific grade of material required rather than a material group P No's and using the actual welding consumables by manufacturer’s brand name rather than by group F No's. The actual welding heat input recorded in the procedure qualification shall be shown on the welding WPQR for each weld pass. The minimum preheat level necessary for the materials shall be recorded on the WPS. The maximum interpass temperature necessary to maintain material properties shall also be defined in the WPS. The qualification record shall record the actual preheat level, the actual interpass temperatures recorded and the welding heat input in kJ/mm. Any decrease of preheat or interpass temperature, during production welding, below the WPS specified minimum value requires re-qualification. Any increase in preheat or interpass temperature during production welding, above the maximum figure qualified by the Weld Performance Qualification Record (WPQR) shall necessitate re-qualification.

9.2

Fully Welded Valve Design As required by ASME VIII Div. 1 Part UCS-56, valve body welds shall undergo Post Weld Heat Treatment (PWHT), dependent upon the valve body thickness. Welding and PWHT shall be carried out in such a way to prevent any damage to the valve’s internal soft materials. Where PWHT is not possible due to potential damage to valve’s internal soft materials, the VENDOR is required to carry out an Engineering Critical Assessment (ECA) to include the below actions, which shall be subject to CLIENT/EPCM review and approval: a) VENDOR shall provide a procedure for assessing the final closure welds that cannot be subject to PWHT b) VENDOR shall utilise approved welders and welding procedures c) WPQR shall demonstrate acceptable hardness and impact test values

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d) Vendor shall provide references from equivalent projects for similar valves (size, material and pressure class) with high body wall thicknesses e) Crack Tip Opening Displacement (CTOD) testing shall be carried out and Finite Element Analysis (FEA) / ECA shall be performed for each valve size, rating and body thickness.

9.3

Weld Overlay Hard facing overlay requirements of Stellite for gate, globe and check valves shall be specified by the applicable Trim Number on the Valve Purchase Descriptions. 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. Alternative weld overlays to those specified in the Valve Purchasing Description shall be submitted to the CLIENT/EPCM for approval prior to use.

9.4

Weld Repairs

9.4.1

General Requirements Repairs shall be undertaken in accordance with ASME B16.34 Section 8.4. All welding repair procedures shall be qualified in accordance with the requirements of ASME Pressure Vessel Code Section IX as amended by this specification. For repair of weldments the original procedure shall be re-assessed and modified if the nature of defects suggests that they are not purely welder induced Weld repairs are permissible for cast valve bodies and bonnets only, in accordance with the provisions of their respective standards and approved WPS. Repairs shall be post weld heat treated if required by the product specification. For cast carbon steel, any subsequent PWHT shall be at a temperature lower than the tempering temperature. Repairs of body castings by peening or impregnation are prohibited. Weld repairs on forgings is not allowed. Defects shall be removed by grinding or by gouging followed by grinding. All excavations shall be subject to 100 % DPI or MPI in accordance with Section 10 prior to welding to ensure that the defect has been completely removed. The welding procedures, and qualifications of the welding procedures and welders to be employed in making the repairs, must be in accordance with ASTM A488 or ASME Pressure Vessel Code Section IX. No repairs shall be permitted after the final heat treatment Procedures on valve bodies shall be qualified as a simulation of the repair situation. To cover all situations a shallow repair approx. 20 mm deep in material of at least 30 mm) and a deep repair approx. 40 mm deep in material of at least 60 mm thick) shall be qualified. Actual thicknesses should be selected based on maximum thickness of the valve body.

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Weld repair qualification shall include any heat treatment, NDE and Charpy V-notch impact testing appropriate to the material being repaired. Repair weld procedures shall be qualified on cast test blocks in accordance with this specification. Procedures shall be qualified in the 6G position to qualify for welding in all positions.

9.5

Non-Destructive Examination of Welds All welds shall be subject to 100 % radiography in accordance with the requirements of Section 10.3.

9.6

Charpy V-Notch Impact Testing of Welds Welding procedures and repair welding procedures for items with Charpy V-notch testing requirements are also subject to Charpy testing.

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10.

MATERIAL NON DESTRUCTIVE EXAMINATION (NDE)

10.1

General All NDE shall be performed in accordance with the mandatory requirements detailed in the material standard specification and the supplementary requirements highlighted in this specification. NDE shall be undertaken upon completion of all heat treatment, welding, repairs and subsequent heat treatment. Valves shall be tested and inspected in accordance with their referenced product specification and shall be subject to the following additional non-destructive examination requirements specified in:  Table 7 for Cast Valves  Table 8 for Forged Valves All NDE procedures shall be submitted to the CLIENT/EPCM for review, no NDE shall be performed without prior approval of the applicable NDE procedures.

10.2

Inspection Lots A lot is the designated batch from which the sample percentage for inspection shall be taken. The valves from each PO shall be separated into a particular number of inspection lots using the following constraints: 

Valve Type (ball, gate, globe, butterfly, dual plate check, modular DBB, etc.)



Valve Body Material (carbon steel, stainless steel, titanium, ductile iron, etc.)



Heat Batch (from foundry certificates) or Heat Treatment Batch



Examination Class (as detailed below)

10.2.1 Lot Acceptance Criteria A lot shall be accepted if all of the inspected samples in that particular lot have met the specified acceptance criteria. Where a sample fails to meet the acceptance criteria, then additional samples equal to the original sample number shall be inspected. If these samples meet the acceptance criteria then the lot shall be accepted with the exception of the initially rejected samples. If any of the additionally inspected samples fail to meet the acceptance criteria then 100 % of the lot shall be inspected. Any doubt regarding the interpretation of examination details or lot sizes shall be clarified with the CLIENT/EPCM.

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Table 8 - NDE Requirements for Cast Valves

Material

Classes & Size

Size

Range

(NPS)

NPS (Inch)

Radiography of

Radiography of

Critical Areas

Each Butt-Weld End

Prototype

Production

Prototype

Castings

Castings

Castings

(Note A) (Note A) Impact Tested

(Notes B, C, F & G)

MPI

DPI

MPI

DPI

Production

Bodies, Bonnets, Pressure

Each Butt-Weld End on

Castings &

Containing Parts

all Prototype & Production

Pup Pieces

(All Accessible Surfaces)

Castings & Pup Pieces

(Note E)

(Note E)

(Notes C & D)

DPI

Hard Facing Weld Overlay

(Note H)

CL150 & CL300

≥ NPS 2

100 %

10 %

100 %

10 %

CL600 – CL2500

≥ NPS 2

100 %

100 %

100 %

100 %

CL150 & CL300

≥ NPS 2

100 %

10 %

100 %

10 %

100 %

100 %

100 %

CL600 – CL2500

≥ NPS 2

100 %

100 %

100 %

100 %

100 %

100 %

100 %

100 %

100 %

100 %

100 %

100 %

Carbon Steel

Stainless Steel

100 %

Type 316/316L

Note: Percentages specified in table refer to the number of valves to be examined per inspection lot.

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Table 9 - NDE Requirements for Forged Valves Radiography or Ultrasonic

MPI

DPI

MPI

DPI

DPI

Size Material

Impact Tested

ASME Class

(NPS)

Bodies, Bonnets, Pressure Containing Parts

Each Butt-Weld End

Hard Facing Weld

(All Accessible Surfaces)

on Forgings & Pup Pieces

Overlay

(Note E)

(Note H)

Rating

CL150 & CL300

(Note A)

(Note F)

≤ NPS 1½

-

≥ NPS 2

-

≤ NPS 1½

-

≥ NPS 2

(Note E) -

-

-

100 %

-

-

-

100 %

100 %

-

-

-

100 %

100 %

100 %

-

100 %

-

100 %

≤ NPS 1½

-

-

100 %

-

-

100 %

≥ NPS 2

-

-

100 %

-

-

100 %

≤ NPS 1½

-

-

100 %

-

-

100 %

≥ NPS 2

100 %

-

100 %

-

100 %

100 %

≤ NPS 2

-

-

100 %

-

-

-

100 %

Carbon Steel

CL600 – CL2500

Stainless Steel

CL150 & CL300

100 %

Type 316/316L CL600 – CL2500

Titanium

CL150 & CL300

Note: Percentages specified in table refer to the number of valves to be examined per inspection lot.

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Notes: A.

Forged and cast valves in size range NPS ½ - 1½ in all Classes for the materials listed will not be subject to Radiography or Ultrasonic examination but will be subject to MPI/DPI examination of 100 % of each valve.

B.

Radiography of critical areas for cast valves shall be as defined in ASME B16.34, Figures 6-16.

C.

Radiographic examination, procedure and acceptance criteria in accordance with Section 10.3.

D.

Radiography of butt-weld ends shall be to a minimum distance of 25 mm from each weld bevel after final machining.

E.

The MPI /DPI flaw detection examination procedure and acceptance standards shall be in accordance with Sections 10.7 and 10.7 respectively.

F.

The use of ultrasonic examination of the entire valve body in accordance with Section 10.5 instead of radiographic examination may be desirable under certain conditions of valve geometry or thickness. However, its use is normally restricted to wall thickness greater than 10 mm. Approved qualified procedures shall be used.

G.

For cast valves at all pressure ratings, the CLIENT’S INSTPECTION AUTHORITY shall select castings at random to measure the wall thickness, in order to provide assurance that the castings supplied comply with the minimum wall thickness specified in the relevant standard.

H.

DPI flaw detection examination procedure and acceptance standards shall be in accordance with Section 10.7.

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10.3

Status: IAA

Date: 25 June 2015

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Visual Inspection The entire surface area of all valves shall be visually inspected in accordance with MSS SP-55 for steel castings and in accordance with ASME V Article 9 for all other components.

10.4

Radiography Radiographic inspection shall be applied using the detailed requirements of method, procedures and qualifications laid down in ASME B16.34 Appendix I. The film shall be of a fine grain or ultra-fine grain type. Radiographic sensitivity and density shall be monitored in accordance with ASME Pressure Vessel Code Section V Article 2, but penetrameters shall be of the 'wire type', in accordance with EN 462 Part 1. X-Radiography shall be used where practical. Acceptance criteria shall be as described in ASME B16.34 Appendix I, with the additional requirement that no hot tears, planar defects, cracks, or crack like defects, are acceptable. For all wall thicknesses, the acceptable defect severity level for gas porosity, inclusions and shrinkage type CD shall be Level 2. The acceptance criteria for radiographic inspection of buttwelds shall be in accordance with ASME VIII Div. 1 Para UW51.

10.5

Ultrasonic Examination (UT) Ultrasonic shall be applied using the detailed requirements of method, procedures and qualifications laid down in ASME B16.34 Appendix IV. Ultrasonic testing shall meet the requirements of the ASTM A388 for forgings, bar, plates, tubular products and ASTM A609 for castings. Both shall include straight beam and angle beam examination. Acceptance criteria shall be as follows: A. Ultrasonic Straight-Beam: Any area giving any indication equal to or larger than the signal received from a 6 mm flat-bottom calibration hole shall be cause for rejection. Multiple indications with an amplitude exceeding 50 % of the indication from the calibration hole, accompanied by a loss of back reflection exceeding 50 %, shall also be cause for rejection. Any indication that results in a complete loss of back reflection shall be cause for rejection. B. Ultrasonic Angle-Beam: Indications which are equal to or exceed those obtained from a 60° V-notch 25 mm long and having a depth not greater than 5 % of the nominal wall thickness, or 6.0 mm, whichever is the lesser in a test piece are unacceptable.

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10.6

Status: IAA

Date: 25 June 2015

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Magnetic Particle Inspection (MPI) MPI shall be applied using the detailed requirements of method, procedures and qualifications laid down in ASME B16.34 Appendix II and ASTM E709. The wet particle technique using background paint shall be adopted and the magnetising technique shall be appropriate to the component being inspected. The prod technique shall not be used. Acceptance criteria for castings shall be as described in ASME VIII Div. 1, Appendix 7, Para 7.3a (4), except that linear indications greater than 3 mm, shall not be permitted. Acceptance criteria for forgings shall be in accordance with ASME VIII Div. 1 Appendix 6.

10.7

Dye Penetrant Inspection (DPI) DPI shall be applied using the detailed requirements of methods, procedures and qualifications laid down in ASME B16.34 Appendix III and ASTM E165. Acceptance criteria for castings shall be as described in ASME Pressure Vessel Code Section VIII Div. 1, Appendix 7, Para 7.3a (3). Acceptance criteria for forgings shall be in accordance with ASME Pressure Vessel Code Section VIII Div. 1 Appendix 8.

10.8

NDE Qualifications VENDORs shall use only qualified NDE Operators and, as a minimum, the operators shall be qualified to the appropriate ASNT-TC1A categories. All NDE personnel shall have at least six months post qualifying experience. Interpretation shall be performed by Level III personnel. Current qualifications shall be available for review.

10.9

Surface Defects Surface defects may be removed by grinding in accordance with the product specification provided that the surface discontinuities and finish comply with MSS SP-55. Surface defects shall be completely removed and the ground area blended to give a smooth transition with the surrounding surface. For forgings, repair to defects in parent material by welding is not permitted. For castings, repair to defects in parent material by welding is only permitted with the express written permission of the CLIENT/EPCM.

Specification for the Technical Supply of Valves Revision: P4-0

Status: IAA

Date: 25 June 2015

11.

VALVE INSPECTION & TESTING

11.1

Procedure

WRP-SPC-MTE-GEN-027 Page 54 of 66

Inspection and testing of valves and acceptance criteria shall be in accordance with the requirements of the specific valve design standard, the requirements of the Valve Purchasing Description and the additional requirements of this specification. The VENDOR shall submit for CLIENT/EPCM approval an Inspection and Testing Procedure specific for each type of valve to be tested based on the requirements specified herein prior to commencement of any valve testing. Approved hydro-test procedures shall include the following requirements, additional to those specified by the referenced design standard:  Soft seated ball valves shall be operated, in the dry condition, 3 times minimum (one full operation cycle is defined as from fully open position to fully closed position and back to fully open position), before commencement of all hydro-testing activities  Unless otherwise specified in the Valve Purchasing Description or this specification, all test pressures and durations shall be in accordance with specific valve design standard or testing standard referenced therein  One cavity relief test shall be performed per seat design and rating on all valves in liquid service VENDOR’s Testing Procedures shall take into account the pressure / temperature limitations of pup pieces and buttweld end connections to ensure they do not sustain damage during high pressure testing. Valves shall not be primed or painted prior to the any testing activities. Valve bodies shall not be impregnated with sodium silicate or any other materials in order to prevent leakage during testing. All test results shall be recorded. Any defects found by the INSPECTION AUTHORITY shall be rectified in their presence. Valves shall not leave the VENDOR’s works before all discovered defects have been rectified and the valve has been re-tested.

11.2

Test Water Requirements Hydrostatic tests shall be carried out with potable water containing 1 % by volume of BP NID 260S liquid or other biodegradable wetting agent. Test fluid for carbon steel valves shall be inhibited water with a chloride and fluoride content of 200ppm max.

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The test fluid for Austenitic stainless steel valves shall be inhibited water with a maximum allowable chloride and fluoride content of 25 ppm. The pH of the test fluid shall be between 6 and 8. The temperature of the test fluid shall be between 5 °C and 40 °C. All valves shall be drained immediately after each hydro-testing activity and dried thoroughly.

11.3

Testing Standards The following testing standards are applicable in addition to the valve’s design standard: Valve Type

Design Standard

Testing Standard

Check Valves

API 594

API 598

Plug Valves

API 599

API 598

Gate, Globe & Check Valves

API 600

API 598

Gate Valves

API 602

API 598

Butterfly Valves

API 609

API 598

Ball Valves

API 6D

API 6D / ISO 5208

BS 1873

BS 1873 / EN 12266-1

EN ISO 17292

EN ISO 17292 / ISO 5208

Globe Valves Ball Valves Table 10 – Valve Testing Standards

11.4

S hell Test 84B

All valves shall be subject to a high pressure hydrostatic shell test at 1.5 x Design Pressure of the ASME B16.34 material group pressure at +38 °C. Flanged valves with a single piece body shall be tested using blinds, plugs and / or hydraulic rams on the valve ends. Flanged valves with a split body design shall not to be tested utilising compressive loads on the valve ends (i.e. using plugs and / or hydraulic rams); unless the VENDOR can prove that the applied loads are not detrimental to the design of the split body joints. Buttweld end valves shall be tested using plugs and / or hydraulic rams on the valve ends. Valves are to be tested with blind flanges provided by the VENDOR.

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Whilst carrying out the shell test, the valve shall be inspected for leakage through the stem packing. If a leak is observed, pressure shall be reduced and the stem packing shall be tightened. If this does not stop the leak, this may be cause for rejection. The test shall be carried out with the operator in the half open position for ball and butterfly valves and in a partially opened position for globe and gate valves. Test durations shall be as specified within the standards referenced in Section 11.3. No visible leakage from any external surface of the shell is permitted throughout the duration of the hydrostatic shell test.

11.5

S eat Tightness Testing 85B

11.5.1 T est Direction 126B

For bi-directional gate, plug and ball valves, the body cavity must be filled with test fluid and the valve shall be operated three times before being fully closed. The test pressure shall be applied successively to each side of the closed valve and checked for leakage. For globe and butterfly valves pressure shall be applied in the designed flow direction. For check valves pressure shall be applied opposite to the normal flow direction to close the plate against the seating surface. Double block and bleed valves shall be tested such that each seat is independently tested in both directions, with leakage measured into and from the cavity. DIB valves shall be tested in accordance with API 6D, Appendix H.

11.5.2 S eat Leakage 127B

Seat leakage shall be measured / monitored via the body cavity or drain connection. For valves without a body cavity connection, seat leakage shall be monitored from each seat at the respective downstream end of the valve. All soft seated valves or ‘tight shut-off’ valves shall have a maximum allowable leakage of ‘Leakage Rate A’, which is defined as ‘No visible leakage for the duration of the test’. Metal seated or hard-faced valves, unless specified as ‘tight shut-off’ shall have a maximum allowable leakage specified as ‘Leakage Rate D’, which is 0.1 mm3/s x DN for hydrostatic testing and 30 mm3/s x DN for pneumatic testing. Test durations shall be as specified within the standards referenced in Section 11.3.

11.5.3 H igh Pressure Hydrostatic Testing 128B

The test pressure for a hydrostatic seat test shall be 1.1 x Design Pressure of the ASME B16.34 material group pressure at +38 °C.

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11.5.4 L ow Pressure Pneumatic Testing 129B

The test pressure for a pneumatic seat test shall 6±1 barg, unless otherwise specified in the standards referenced in Section 11.3.

11.5.5 Backseat Testing All gate and globe valves and any other valves supplied with a backseat shall be subject to a backseat tightness test. The backseat test shall be in the form of either a 110 % design pressure hydrostatic test or a pneumatic test at the valve VENDOR’s preference. The valve must be in the fully open position with the stem backseat fully engaged and the packing gland bolting loose. No visible backseat leakage is permitted.

11.6

D isk Strength Test 86B

All Dual Plate Check Valves shall additionally be subject to a hydrostatic disk strength test, applied to 10 % (minimum one valve) for each size, rating and material at 1.5 times the design pressure at 38 °C. Butterfly valves shall be subjected to a hydrostatic disk strength test, applied to 10 % (minimum one valve) for each size, rating and material in accordance with EN 12266-2. Disk strength tests shall be undertaken prior to the valve’s hydrostatic shell and seat tests.

11.7

N itrogen / Helium Gas Leak Test for Valves 87B

When ‘Severe Service’ is stated in the Valve Purchase Description, all valve types (except check valves) shall be subject to Nitrogen / Helium gas leak test performed upon completion of all hydrostatic seat testing. The test shall be applied to 10 % (minimum of one valve) for each size, rating and material, to the conditions stated in the Valve Purchasing Description. The Nitrogen / 1 % Helium mix shall be measured with a mass spectrometer. The testing duration will be in accordance with the EN 12266. Nitrogen leak testing shall consist of testing the valve body and seats for leakage throughout the entire duration of the test. Seats shall be gas tested by a similar method to the pneumatic seat test described in EN 12266. The test pressure in all cases shall be 1.1 x Design Pressure and all detectable leakages shall be recorded. The VENDOR shall submit for CLIENT/EPCM approval, a Nitrogen / Helium gas leak testing procedure based on the requirements specified herein and including the measurement technique applied.

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The acceptance criteria shall be as follows: Test Location Body Joints & Glands Seats

Seat Type

Pressure Rating

All

All

5 Scf / annum

Soft

All

Zero

Metal

≤ CL600

2.0 cc/minute per diameter in DN

Metal

≥ CL900

4.0 cc/minute per diameter in DN

Maximum Acceptable Leakage

Table 11 – Nitrogen / Helium Gas Leak Testing Acceptance Criteria

11.8

T orque Test 8B

All valves shall be subject to an operational torque test, which shall be undertaken directly after completion of the hydrostatic seat test. Torque testing at ambient temperatures, shall be as follows:  With the ball / disc in the closed position and at the test temperature, the valve shall be fully pressurised in four equal increments up to 1.1 x Design Pressure as shown in the Valve Purchasing Description. A one minute minimum stabilisation period shall be allowed after each pressure increase.  The valve shall be cycled through 3 open/shut operations. The torque or direct force required to operate the valve shall then be measured at seat breakout, mid-range, and reseating and shall be recorded.  Similar tests performed earlier (type test) on valves may be submitted for review in order that this requirement be waived. Type tests will only be accepted if the valve tested is identical in design and materials of construction including seal and seat materials to the valve being supplied for the production batch This will be achieved, as follows:  The valve shall be pressurised from one side only to the high pressure hydrostatic seat test pressure with the opposing side at atmospheric pressure.  The pressure shall be allowed to stabilise for one minute and the valve then operated to the fully open position.  The torque or direct force required to operate the valve shall be measured at seat breakout and mid-range.  The test above shall be repeated with the pressure applied to the other side of the valve.

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WRP-SPC-MTE-GEN-027 Page 59 of 66

For manual valves the operating force measured as a torque shall be converted to the force required to operate the valve. This force shall not exceed 350 N. While conforming to the restrictions on handwheel diameter or lever length)

11.9

L ow Temperature Type Testing of Valves 89B

All valves in low temperature service below -40 °C shall be subject to low temperature testing in accordance with Appendix A. Valves with ‘LOW TEMPERATURE’ and ‘EXTENDED BOLTED BONNET’ specified in the Valve Purchase Description are to be operable at the specified minimum design temperature and will require complete low temperature testing as per Appendix A requirements. Valves with ‘LOW TEMP’ specified, but without the requirement for an extended bonnet in the Valve Purchase Description are non-operable but shall seal and survive at the specified minimum design temperature. These valves are only subject to a shell test at both the ambient and low temperature conditions as per Appendix A requirements.

Specification for the Technical Supply of Valves Revision: P4-0

12. 12.1

Status: IAA

Date: 25 June 2015

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M ATERIAL IDENTIFICATION 1B

C ertification 90B

All materials shall be certified in strict accordance with EN 10204 and documentary evidence shall be provided as part of the PO documentation. All material certificates shall be originals or certified copies. As described in the Quality, Inspection & Surveillance Requirements - Contractors & Subcontractors, WRP-PCD-QAC-GEN-002, Test and Material Certificates for all pressure retaining / containing components (including bolting) of manual valves shall be in accordance with EN 10204 type 3.1. As a minimum Certification shall include the following:  Name of Vendor  Valve Serial Number  Name Raw Material Source or Product Form  PO Number, Date & Item Description  Material Specification, Grade & Heat Treatment  Dimensions (length, width, diameter, NPS, wall thickness, etc.).  Heat Number & Charge Number  Chemical Composition (Based on Product Analysis)  Mechanical Test Data (Yield Strength, Hardness, etc.)  Inspection & NDE Results  Carbon Equivalent for Carbon Steel Components All other non-pressure retaining / containing components shall be in accordance with EN 10204 type 2.2. Material certificates for dual certified stainless steel materials shall indicate compliance with the requirements of both grades of stainless steel as stated in the stock code description. All certificates shall state the manufacturer’s name and location, all forging and plate certificates shall be from original steel manufacturers. Certificates shall include the VENDOR’s purchase order number and purchase order item number.

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12.2

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T raceability 91B

Material traceability requirements are detailed in the Quality, Inspection & Surveillance Requirements – Contractors & Subcontractors, WRP-PCD-QAC-GEN-002.

12.3

M arking 92B

12.3.1 B ody Marking 130B

Marking shall be as per the relevant component design standard, MSS SP-25 and with the requirements as stipulated herein. As a minimum, the valve shall be marked with the following information: 

VENDOR’s Name or Trademark



Valve Serial Number



Material Designation for Body & Trim



Melt Identification / Heat Number



Purchase Order & Item Number



Commodity Code Number



Rating Designation



Nominal Valve Size / Trim Size



Flow Direction Arrow (for uni-directional valves)

Markings shall be made at the following locations: 

Flanged valves - on the edge of the flange



Socket weld / threaded valves - on the hexagon or circular end



Buttweld valves - on body where wall thickness is greatest and where the number is most likely to be visible after installation and which will not act to the detriment of the product

Valves manufactured from impact tested carbon steel, high yield carbon steel, duplex and austenitic stainless steels, titanium, and copper nickel shall be vibro etched. All other materials shall be marked by cold stamping using round nosed low stress stamps. Cold stamping is not permitted upon the valve body. Any valves limited in pressure / temperature rating shall have the maximum pressure in barg at the maximum operating temperature marked in place of the valve’s class rating e.g. 248 barg at 100 °C. The use of markings other than those specified herein may involve rejection of the component.

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12.3.2 N ameplates 13B

Valve nameplates shall be permanently fixed to the valve using rivets or screws, which shall in no way affect the pressure containing capability of the valve. The tag plate shall be made from a suitable corrosion resistant material and shall be free from sharp edges or burrs. Method of attaching the nameplate to the valve shall not compromise the minimum required wall thickness of the valve body. For valves being installed in above ground locations or in pits, the nameplate shall be affixed to the valve body. For valves being installed in below ground (buried) locations, in addition to the nameplate on the valve body, a second identical nameplate shall be affixed to the stem protector, located approximately 500 mm below the top connection to the actuator. Where additional tagging is required in addition to the VENDOR’s standard tagging, then a corrosion resistant metal tag 50 x 20 mm wired to the valve with corrosion resistant wire shall be used. As a minimum the valve nameplate shall contain the following information: 

VENDOR’s Name or Trademark



Valve Serial Number



Tag Number



‘CE’ Marking (EC/97/23)



Commodity Code Number



Valve Type



Design Code



Nominal Valve Size / Trim Size



Rating Designation



Material Designation for Body, Trim, Seats, Seal & Packing



Pressure / Temperature Rating



VENDOR’s Model, Type & Serial Number



Inspection Release Certificate Number



Date of Manufacture (Month & Year)



Length of Extended Bonnet / Stem



Wall Thickness (where applicable for buttweld end valves)

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12.4

Status: IAA

Date: 25 June 2015

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P ositive Material Identification (PMI) 93B

Positive Material Identification shall be carried out in accordance with the Specification for Positive Material Identification, WRP-SPC-MTE-GEN-035.

.

Specification for the Technical Supply of Valves Revision: P4-0

13.

Status: IAA

Date: 25 June 2015

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Q UALITY ASSURANCE 12B

VENDORs shall operate an accredited Quality Management System (QMS) ensuring that the technical requirements of this specification and the requirements of the Quality, Inspection & Surveillance Requirements – Contractors & Subcontractors, WRP-PCD-QAC-GEN-002 are complied with in full. It is the VENDOR’s responsibility to ensure that all SUB-VENDORs comply with the requirements of this specification and the Project’s quality requirements. The VENDOR shall provide copies of their and all SUB-VENDOR’s ISO 9001 certification, ensuring they are valid and up to date copies. .

Specification for the Technical Supply of Valves Revision: P4-0

14.

Status: IAA

Date: 25 June 2015

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P REPARATION FOR SHIPMENT 13B

14.1

P ainting 94B

All ITCS valves shall be prepared and painted for external protection by the valve VENDOR in accordance with either the Paint Specification, WRP-SPC-MTE-GEN-001, applicable for above ground valves or the Specification for Protective Coatings (Paint) for In-Plant Buried Piping and Mainline Pipeline Appurtenances, WRP-SPC-MTE-PLG-011 applicable for buried valves. Painting shall only be applied after successful completion of all NDE, testing and inspection. The interior, threaded portions, bevelled ends, flange gasket contact faces and various valve identifying markings shall not be painted. All Austenitic stainless steel and Titanium valves shall be supplied in the un-painted condition.

14.2

P rotection 95B

Valves shall be packed ready for export in a manner which allows easy handling and prevents damage; VENDOR shall submit their packing procedure for approval in the bid, in accordance with the requirements specified within the PO and / or Requisition. The VENDOR shall be responsible for the protection of all items during transit and storage, but as a minimum the following will apply. Socket weld / threaded valves ends shall be protected with plastic end protectors (minimum 5 mm thick) fitted and secured with water proof tape in order to prevent damage during shipment. Butt weld ends of valves shall be supplied with heavy duty plastic protective plugs or caps. For bevelled ends, the caps shall protect the full area of the bevel. All flange gasket contact surfaces shall be protected with 6 mm thick plywood discs bolted to each flange in at least four locations. If valves are shipped loose, hand-wheels or wrenches shall be removed from valve stems and securely wired to the body with non-corrosive metal wire. The exposed stem surfaces / threads shall be protected with plastic covers or heavy duty tapes having been greased first. The handwheel / wrench securing nut shall be re assembled on the valve stem. Austenitic stainless steel items shall be protected from chloride attack which can occur from exposure to salt water spray or the atmosphere during shipment. Valve stem assemblies / stuffing boxes shall be protected against the ingress of water using plastic bags, caps or tapes (with chlorine free adhesive). All machined surfaces shall be coated with a light film of high viscosity rust inhibiting oil suitable for -20 °C to 50 °C.

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14.3

Status: IAA

Date: 25 June 2015

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P reparation for Dispatch 96B

Gate, globe, check and butterfly valves shall be dispatched in the fully closed position. Plug, diaphragm and ball valves shall be despatched in the fully open position. In general, despatch of valves shall be in accordance with the specification to which it is manufactured, as a minimum, the relevant sections of BS 1133 shall apply.

14.4

H andling and Storage 97B

Materials shall be handled and stored as such that mechanical damage, contamination and corrosion are avoided. The VENDOR shall submit to CLIENT/EPCM for approval, detailed procedures describing the proposed methods for handling and storage. Austenitic stainless steel valves shall be segregated from carbon steel valves and shall not be handled using carbon steel devices. All means of conveyance used for shipment and transportation of the supplied items e.g. rail cars, trucks, lighters, ships, etc. shall be cleaned of debris, or any other item or substance, that may possibly contaminate, or cause damage to, the supplied items during loading/off-loading, or whilst in transit. All packing and preservation shall be suitable for outside storage in Turkey for at least six months.

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Appendix A - Low Temperature Testing of Valves

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A1.

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LOW TEMPERATURE TESTING OF VALVES The intention of this test procedure is to demonstrate the acceptance performance of the valve design at the low design temperature as specified on the Valve Purchase Description. Performance of the representative valve is tested at low temperature in order to:

A2.



Prove that the valve remains operable from open to closed, and closed to open, within the limits of the operator



Ensure that body joints, end connections, and stem seals do not exceed the external leakage rate specified in this specification



Prove that the leakage across the valve seats does not exceed the leakage rate specified herein

SELECTION OF VALVES AND QUANTITIES FOR TESTING This specification is to be used as a Type Approval Test (TAT); the valves on an order shall be separated into inspection lots, with a different lot for each discrete type. 

Valve type (ball, butterfly, gate, globe, etc.) and valve style



Valve nominal size and pressure class



Basic material type (e.g. ITCS, Austenitic stainless steel)

The sample lot size shall be 10 %, with a minimum of one per valve type, style, size, pressure class rating and material. The valves to be tested shall be selected at random from the lot being tested by the CLIENT/EPCM representative. In order to fully qualify the full range of valves, the valves selected for test shall include the range of sizes to cover the pressure ratings, design variations and material options contained within the Purchase Order and / or Requisition description. The criteria for selection of test valves shall be as follows: 1. One test valve of each pressure class, size and design and by VENDOR 2. One test valve may be used to qualify valves larger than the test valve, not exceeding twice the test valve size. An NPS 16 valve will qualify larger sizes up to and including NPS 30. For valves > NPS 30 individual valves tests shall be completed 3. One test valve may be used to qualify valves with higher pressure ratings of one additional pressure class only The seat leakage of bi-directional valves shall be tested in both directions. Valves with a preferred high pressure side (as marked on the body) or uni-directional valves shall be tested from that preferred side.

Specification for the Technical Supply of Valves Revision: P4-0

A3.

Status: IAA

Date: 25 June 2015

WRP-SPC-MTE-GEN-027 Page 3 of 18

SAFETY Prior to low temperature testing each valve shall have been successfully pressure tested as described in this specification. Due to the hazardous nature of gas testing, under no circumstances shall this pre-testing be waived. To prevent brittle fracture, the pressure envelope materials, i.e. body, transition pieces, end adaptors, bonnet, extended bonnet and bolting shall be qualified by impact testing as specified in the Valve Purchasing Description. Proof of prior pressure testing to design code and specifications and proof of impact testing, shall be by authorised certificates of test results to the satisfaction of the INSPECTION AUTHORITY.

A4.

GENERAL REQUIREMENTS

A4.1

Test Facility The valve shall be tested at the VENDOR’s own test facilities or at an independent testing facility. The test(s) shall be witnessed by the CLIENT/EPCM or designated independent INSPECTION AUTHORITY. All contacts, concerning the test arrangements shall take place directly between the VENDOR and the testing facility / institute. The VENDOR shall supply the testing facility / institute with all the relevant documentation.

A4.2

Valve Test Record/Certificate During the test, all observations, data and results shall be recorded in sequence with dates and time and may be supported by photographs. The test results and documents shall be compiled and filed by the VENDOR for reference.

A4.3

Acceptance Requirements A lot shall be accepted if all the samples of the lot meet the specified acceptance criteria. If a valve fails any of the test requirements, the valve shall be rejected; the cause of the failure shall be investigated and a detailed valve component inspection shall be mandatory. The valve shall be disassembled and possible failed valve parts, e.g. seats, seals, gaskets, etc. shall be checked for excessive wear and/or permanent deformation. Re-testing at the specified temperature is mandatory for those valves where the measured-forces / torques during the operational test or seat test exceed the specified limit. When a re-test is necessary the test report shall be submitted to the CLIENT Representative for information/approval. In a case of failure and a tested valve fails to meet the acceptance criteria, an additional valve (the same size, pressure class and material), shall be tested; and/or the repaired valve shall then be retested.

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If these samples meet the acceptance criteria, the lot shall be accepted with the exception of the initially rejected items. If any of the additionally inspected samples fails to meet the acceptance criteria, then 100 % of the lot shall be inspected or, at the CLIENT/EPCM Representative’s discretion, the entire lot shall be rejected. The re-test shall take place at the same testing facility where the previous test was carried out. If the test equipment fails or a shortage of gas (bottle/supply) occurs, the test shall be aborted and the valve shall be submitted to a re-test.

A4.4

Test Rig, Valve Connections and Supports A schematic of a low temperature test rig is shown in Section A7 of this Appendix. The valve and the tank shall be strong enough to withstand all forces exerted during handling of the valve. The test rig shall be capable of testing the valve in both directions. Brackets to support the valve in the test rig shall be fixed to the valve end covers or alternatively clamped to the body. There shall be no supports mounted to the stem/bonnet extension of the valve. The valve to be tested shall be flanged type. The valve ends shall be equipped with suitable end covers, capable for testing in both directions. Both blind flange covers shall be provided with a pressure/vent connection and a thermocouple connection for the closure member of the valve. The gaskets for the valve end blind flanges shall be spiral wound with ASTM A240 type 316L windings, inner and centring ring and graphite filler. Deviations and / or other testing systems are subject to approval by the CLIENT/EPCM.

A4.5

A4.6

Selection of Cooling Medium Service and Test Temperature

Type of Coolant Medium

from -30 °C down to -49 °C

Alcohol with ice, liquid nitrogen or nitrogen gas

from -50 °C down to -196 °C

Liquid nitrogen with or without alcohol, or nitrogen gas

Selection of Leak Test Medium The leak test medium can be made-up from the following: 1. Helium 2. Pure nitrogen 3. 99 % nitrogen mixed with 1 % helium (used as a trace for leak detection purposes)

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Status: IAA

Date: 25 June 2015

WRP-SPC-MTE-GEN-027 Page 5 of 18

For tests at or close to the temperature of -196 °C, only helium shall be used. Pure nitrogen is only acceptable for seat testing if agreed by the CLIENT Representative. The test medium shall be certified before commencement of testing. The Test Facility owner shall ensure that appropriate safety measures are put in place, due to the hazardous nature of pneumatic testing.

A4.7

Test Instruments and Equipment Suitable temperature recording equipment and thermocouple connections shall be used for monitoring the temperature throughout the test. The scale of the test pressure gauges shall not exceed twice the range of maximum test pressure. Note: All digital indicators shall have full scale reading. The leakage through the test valve shall be measured by means of one of the following devices: 

Measuring cylinder in a water tank



Gas flow meter soap film type



Gas flow meter (interconnected to a computer system with screen display)



Rota-Meter type flow meter for high leakage rates and large valve sizes

Fugitive volatile emissions from the stuffing box, body/bonnet and cover connections of the valve shall be detected by means of a portable helium mass spectrometer leak detector using a sniffer probe (e.g. the brand Leybold, types: UL-100 plus, UL-200 or UL-200-dry or the brand Varian helitest, model 979, etc.). All measuring equipment and instruments shall have a current system calibration certificate.

A5.

TESTING

A5.1

General The valve shall be visually inspected for any damage and defects. The valve and test equipment/system shall be dry, thoroughly cleaned, degreased and dust and oilfree. Prior to commencement of the tests the valve(s) shall be unpainted and without external or internal protective coating. If a protective coating must be removed, the valve shall be disassembled and the valve body and internals shall be thoroughly cleaned and degreased with inhibited methylene-chloride or tri-chlorethylene. Re-assembly of the valve(s) shall be carried out at a clean location. After re-assembly the valve shall be re-qualified/tested to the requirements of the applicable design standard and specification.

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Status: IAA

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WRP-SPC-MTE-GEN-027 Page 6 of 18

The tests shall be carried out in the sequence as stated in BS 6364 and Section A8 of this Appendix. The tests shall be consecutive with a minimum in delay. Throughout the test, the temperature of the following measuring points shall be measured and recorded:

A5.2



Coolant



Valve body (outside)



Stuffing box or stem packing area (outside), as near as possible to the closure member (i.e. disc, wedge or ball)



The room temperature shall also be recorded

Operation of the Valve (Open and Close) The time to open and close wrench-manual operated valves, hand wheel and gear-operated valves shall be the shortest possible time specified by the valve VENDOR or CLIENT Representative. The actual forces and torques (Break-Out, Open/Closed and Running) applied at the valve operator, during the maximum rated body differential test pressures for the design temperature range, as defined in ASME B16.34, shall not exceed the torque values as per the applicable design standard/specification and a maximum operating force of 350 N at the lower design temperature. The opening force, closing force and torque of each first operation shall be measured and recorded. During the valve seat test, after the first and last pressure increment, the valve shall be fully opened and closed five times. Manually operated valves shall be operated without the use of spanners (wheel keys) or any other extension devices. The use of air-tool equipment for operation of the valve during this test is acceptable.

A5.3

Test Pressures The maximum body test pressure and seat test pressure shall comply with the applicable valve design code specified in the purchase order description. Materials of construction are listed by material group in ASME B16.34 table 1. For metal seated valves, the nominal pressure/temperature rating at the applicable test temperature shall be selected from ASME B16.34 Table 2 for the respective material group. With this nominal pressure/temperature rating both the shell (body) and seat test pressures shall be calculated in accordance with EN 12266-1. When the valve size and/or rating would seriously hamper the practicality of the test a reduced test pressure may be considered, however this is subject to approval by the CLIENT Representative. The test pressure shall preferably be raised in 3 equal increments minimum. However, the VENDOR may decide to perform the test in 4 or 5 equal increments.

Specification for the Technical Supply of Valves Revision: P4-0

A5.4

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Date: 25 June 2015

Page 7 of 18

Test Temperature The required valve test temperature is defined in the requisition and/or purchase order and is equal to the stated temperature for low temperature service. The difference in temperature between valve body and closure `member shall not deviate more than 5 % from the lower design temperature or 5 °C, whichever is the greater.

A5.5

Cooling Down During the cooling down period the temperature shall be measured and recorded at least every 10 minutes. The records may be provided on separate sheets. The valve shall be installed in the test tank and cooled down with the stem in the vertical (upright) position. When immersed in the coolant, the top of the valve body/bonnet shall be just covered. The stem seal(s) and/or stuffing box shall be above the maximum cold fluid level in the tank. To prevent the formation of moisture in the valve during the cooling operation, a minimum pressure purge of 0.5 barg helium or nitrogen gas through the valve shall be maintained with the valve in half open position. Soft-seated valves shall be kept in the fully open position and shall only be operated (closed and opened) regularly, when cavity purging is required. The test may commence when the valve body and the internals have reached the specified test temperature (see section 5.4 of this appendix).The purge shall be switched off. Stabilise the temperature for 5 minutes. The valve shall then be in the fully open position. The complete system including the test valve/cavity shall be de-pressurised.

A5.6

Ambient Testing

A5.6.1 High Pressure Seat Test With the valve in the closed position, pressurise one side of the valve to the ambient hydrostatic seat pressure stated in the valves design code with the other side at atmospheric pressure. Following a stabilising period of 1 minute, the valve seat leakage shall be measured over a period of 1 minute and recorded. This test shall then be repeated for the other side on bi-directional valves. For allowable leakage shall be as per Section A6 of this Appendix.

A5.6.2 Low Pressure Seat Test The seat leakage test in the above Section shall be repeated with the valves pressurised at 7 barg. For allowable leakage rates shall be per Section A6 of this Appendix.

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Page 8 of 18

A5.6.3 Shell Test With the valve in the half open position, the valve shall be pressurised in increments of 10 barg and held for 1 minute at each increment up to the maximum pressure of 1.1 times the maximum design pressure stated in the design code. Following a 1 minute stabilising period, the following specific components shall be checked for leakage and/or porosity: 

Body/bonnet joint or body/cover flanges



Stem extensions(connections)



Stuffing box-stem seal and gland (follower)



Around the end flanges



Tubing or piping connections to the test rig

Check for leakage during a minimum period of 5 minutes. The leakage shall be measured using a mass spectrometer and recorded. For allowable leakage rates shall be as Section 6 of this Appendix.

A5.7

Low Temperature Testing

A5.7.1 High Pressure Seat Test The test valve shall be in the closed position and subjected to the test pressure in 3 equal increments minimum. (See Section A5.3 of this Appendix). The downstream side of the valve shall be depressurised at the beginning of the test and after each pressure increment. After the last increment the test pressure shall be maintained. After the pressure has stabilised, the leakage through the valve shall be recorded at each pressure increment during a period of 3 minutes. This test shall then be repeated for the other side on bi-directional valves. For allowable leakage rates shall be as per Section A6 of this Appendix.

A5.7.2 Low Pressure Seat Test The seat leakage test in the above Section shall be repeated with the valves pressurised at 7 barg. For allowable leakage rates shall be as Section A6 of this Appendix.

A5.7.3 Shell Test With the valve ball/gate/disc in the half open position, the temperature shall be reduced until the test temperature on the valve thermocouples is established. The valve shall then be allowed to ‘soak’ at the test temperature for a minimum of 30 minutes to verify a stabilised temperature. The valve shall then be pressurised in increments of 10 barg and held for 1 minute at each increment up to 1.1 times the maximum design pressure stated in the valve design code. When the

Specification for the Technical Supply of Valves Revision: P4-0

Status: IAA

WRP-SPC-MTE-GEN-027

Date: 25 June 2015

Page 9 of 18

full test pressure is reached, the valve shall be held for a period of 1 hour and the leakage rate measured with a mass spectrometer. For allowable leakage rates shall be as Section A6 of this Appendix.

A5.8

Operational Test (Maximum Pressure) The test valve shall be in the closed position. The downstream side of the valve shall be de-pressurised. One side of the valve, i.e. the preferred side, shall be pressurised. The pressure shall be the maximum allowable rated seat test pressure. Possible stem and/or body-bonnet leakages shall be checked for prior to the operation testing. The pressure shall be stable for one minute at the beginning of the operation of the valve. The valve shall be operated (open and immediately closed) 5 full strokes. The torque (force) of the (open and close) operation of the valve shall be recorded. The maximum allowable force applied at the wrench or hand wheel is 350 N.

A5.9

Warming-Up After completion of the leakage tests, the valve shall be in the half open position, (however soft seated ball valves shall be set in the fully open position, to prevent possible damage to the soft seats), de-pressurised (including any valve cavity) and be kept outside the test tank for warming-up to ambient temperature. A forced warming-up, e.g. using hot-air blowers or heaters, is not allowed. However, air circulation around the valve at room temperature caused by fans is acceptable.

A5.10 Final Inspection When the valve is at room temperature the valve and internals shall be cleaned and dried. End connectors and other test rig equipment shall be removed from the valve. After successful completion of all tests the valve need not be disassembled for component inspection but shall be visually inspected only.

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A6.

MAXIMUM ALLOWABLE LEAKAGE RATES FOR VALVES

A6.1

Shell (Body) Leakage Test Depending on the media and service application, the actual body leakage rate for valves, tested at both ambient and the specified low temperature conditions, shall be zero (see note 1).

A6.2

Seat Leakage Test Allowable seat leakage (both seats), shall be in accordance with EN 12266-1, pneumatic tested at ambient temperature, specified low pressure and rated seat test pressure: Valve Seat Type Valve Type Ball, Gate, Globe

0 mm³/s*NPS

Metal / Soft Seated (Fire Safe) N/A

Butterfly TSO

0 mm³/s*NPS

0 mm³/s*NPS

0 mm³/s*NPS

0 mm³/s*NPS

0 mm³/s*NPS

0.3 mm³/s*NPS (EN 12266-1 table A5)

Soft Seated

Metal seated 0.3 mm³/s*NPS (EN 12266-1 table A5)

(Preferred Flow Direction)

Butterfly TSO (Non-Preferred Flow Direction)

Allowable seat leakage (both seats), tested with nitrogen / helium at specified low temperature, specified low pressure and rated seat test pressure: Maximum Allowable Leakage Rates for Valves with Seat Type Valve Type Gate, Globe, Ball

Resilient (Soft) Seated 33 mm³/s*NPS

Fire Safe (Metal/Soft seated) 67 mm³/s*NPS

100 mm³/s*NPS

Butterfly – TSO (Note 4)

33 mm³/s*NPS

67 mm³/s*NPS

100 mm³/s*NPS

Metal Seated

Notes: 1. The terminology ‘no visually detectable leakage’ or ‘zero leakage’ is equitable to 0.27 Scc/min (5 Scf per annum) 2. The valve nominal size NPS [in inches] is the nominal bore or reduced (nominal) bore referred to as DN in BS 6364 Appendix A 3. For valves capable of sealing in both directions, refer to BS 6364 Appendix A paragraph 3.1.4.d 4. The maximum allowable seat leakage rate for butterfly valves in the non- preferred flow direction shall not exceed 100 mm³/s *NPS

A7.1 Typical Test Rig During Valve Cooling

the valve body.

TYPICAL TEST RIG DURING VALVE COOLING/TESTING

into the insulated tank (allowing it to boil off) will sustain the required temperature during pressure testing of

A7.

Having achieved the initial required test temperature of the valve, the controlled addition of liquid nitrogen

T1 Thermocouple (Body)

Date: 25 June 2015

if required)

Insulated Tank

Test Valve

T2 Thermocouple (Bonnet)

Status: IAA

(compressor boosted

Insulated Cover

Pressure Gauge

Revision: P4-0

Liquid Nitrogen

Regulator

Bottle Valve &

2nd Control Valve

Specification for the Technical Supply of Valves WRP-SPC-MTE-GEN-027 Page 11 of 18

if required)

. (Compressor boosted

seats

rates across the

measure leakage

Manometer to

Flowmeter or

Date: 25 June 2015

Insulated Tank

Test Valve

Control Valve

Status: IAA

+ 1% Helium Gas Mix.

Insulated Cover

Pressure Gauge

Revision: P4-0

Certified 99% Nitrogen

Regulator

Pressure Gauge

A7.2

Bottle Valve &

2nd Control Valve

Specification for the Technical Supply of Valves WRP-SPC-MTE-GEN-027 Page 12 of 18

Typical Test Rig During Valve Testing

Specification for the Technical Supply of Valves Revision: P4-0

A8.

Status: IAA

WRP-SPC-MTE-GEN-027

Date: 25 June 2015

VALVE TEST RECORD/CERTIFICATE

Valve Make:

Valve Type:

Valve Style No:

Valve Figure No:

Valve Sealing (a):

Uni / Bi directional

NPS:

Class Rating:

Temperature Range:

Design Standard:

Commodity Code

Body Material:

Seat Material:

Seat Facing Material:

Date of Testing:

Valve is Tested in Accordance with:

WRP-SPC-MTE-GEN-027

PURCHASER: REMARKS: (a) Delete what is not applicable.

Report Reference No:

Purchase Order No:

Page 13 of 18

Specification for the Technical Supply of Valves Revision: P4-0

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Date: 25 June 2015

Page 14 of 18

Test Results Testing at Ambient Temperature [A5.6]

Specified Limit

Actual Measured

Actual ambient temperature:

N.A.

ºC

1st Operational test [A5.8] 5 full strokes: Operational force to open and close: Diameter hand wheel / wrench

350/350 N 750/450mm

/ mm

barg mm³/s max Nitrogen/heli um(a)

barg mm³/s max

barg mm³/s max Nitrogen/heli um(a)

barg mm³/s max

barg zero mm³/s max Helium

barg mm³/s max

350/350 N mm

/ mm

Seat test [A5.6.1/2] in preferred flow direction at Maximum differential pressure Leakage rate Leak test medium: Seat test [A5.6.1/2] in non-preferred flow direction at Maximum differential pressure Leakage rate Leak test medium: Shell test [A5.6.3] Maximum pressure Leakage rate Leak test medium: 2nd Operational test [A5.8] 5 full strokes: Operational force to open and close: diameter hand wheel / wrench

N

N

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Cooling Down [A5.5]

Page 15 of 18

Specified Limit

Actual Measured

Testing at low temperature [A5.7]: 3rd Operational test [A5.8]: Operational force to open & close Diameter of Hand wheel Specified and actual low temperature:

ºC

ºC

Seat test in preferred flow direction [A5.7.2]: Leak test medium: 1st Increment (low differential pressure) Leakage rate

Nitrogen/helium (a) barg mm³/s max

barg mm³/s max

2nd Increment (medium diff. Pressure) Leakage rate

barg mm³/s max

barg mm³/s max

3rd Increment (max. differential pressure) Leakage rate

barg mm³/s max

barg mm³/s max

Specification for the Technical Supply of Valves Revision: P4-0

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Date: 25 June 2015

Cooling Down [A5.5]

Page 16 of 18

Specified Limit:

Actual Measured:

ºC

ºC

Testing at low temperature [A5.7]: 3rd Operational test [A5.8]: Operational force to open & close Diameter of Hand wheel Specified and actual low temperature: Seat test in preferred flow direction [A5.7.2]: Leak test medium: 1st Increment (low differential pressure) Leakage rate

Nitrogen/helium (a) barg mm³/s max

barg mm³/s max

2nd Increment (medium diff. Pressure) Leakage rate

barg mm³/s max

barg mm³/s max

3rd Increment (max. differential pressure) Leakage rate

barg mm³/s max

barg mm³/s max

Cooling Down [A5.5]:

Specified Limit:

Actual Measured:

Testing at low temperature [A5.7]: 4rd Operational test [A5.8]: Specified and actual low temperature:

ºC

ºC

1st Increment (low differential pressure) Leakage rate

Nitrogen/helium (a) barg mm³/s max

barg mm³/s max

2nd Increment (medium diff. pressure) Leakage rate

barg mm³/s max

barg mm³/s max

3rd Increment (max. differential pressure) Leakage rate

barg mm³/s max

barg mm³/s max

Seat test in non-preferred flow direction [A5.7.1/2]: Leak test medium:

Shell Test [A5.7.3]:

Specified Limit:

Actual Measured:

Maximum pressure

barg

barg

Leakage rate

zero mm³/s max

mm³/s max

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Status: IAA

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Date: 25 June 2015

Cooling Down [A5.5] Leak test medium:

Page 17 of 18

Specified Limit:

Actual Measured:

Helium

4th Operational test [A5.8] 5 full strokes: Operational force to open and close:

350/350 N

/

Diameter hand wheel/wrench

mm

mm

Warming Up [5.9]: Actual ambient temperature:

Specified Limit: N.A.

N

Actual Measured: ºC

Seat test in preferred flow direction: [5.7.1/2]: Leak test medium: Maximum differential pressure

Nitrogen/helium (a) barg

barg

Leakage rate

mm³/s max

mm³/s max

Maximum differential pressure

Nitrogen/helium (a) barg

barg

Leakage rate

mm³/s max

mm³/s max

Nitrogen/helium (a) barg

barg

Seat test in non-preferred flow direction: [5.7.1/2]: Leak test medium:

Shell test [5.7.3] Leak test medium: Maximum pressure Leakage rate Leak test medium

zero mm³/s max Helium

mm³/s max

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Status: IAA

Date: 25 June 2015

WRP-SPC-MTE-GEN-027 Page 18 of 18

VALVE TEST RECORD / CERTIFICATE Visual Inspection / Examination [A5.1 and A5.10]: Observations and findings:

Valve Disassembled: Yes / No

Condition of Components:

Any other comments and/or additional test data:

Tested / Reported by:

Signature: Date:

Inspection Authority:

Signature: Date:

Witnessed by:

Signature: Date:

REMARKS: a) The numbers between brackets [ ] refer to the relevant sections in this Appendix.