KOC-MP-033 Part1_Rev 1 - Ball Valve.pdf

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(;j.~.J1) ~~\.k.aJ a<J ~ KUWAIT OIL COMPANY (K.S.C.)

STANDARDS PUBLICATION

KOCSTANDARD

FOR

VALVES: PART 1-BALL VALVES

DOC. NO. KOC-MP-033 Pt. 1

STANDARDS TEAM

DOC. NO. KOC·MP-033 PART 1 Page 1 of 37 REV. 1

STANDARDS PUBLICATION

KOC STANDARD

FOR

VALVES:PART1-BALLVALVES

DOC. NO. KOC-MP-033 PART 1

STANDARDS TEAM

DOC. NO. KOC-MP-033 PART 1 Page 2 of 37 REV. 1

KOC STANDARD

FOR

VALVES: PART 1 - BALL VALVES

1 31.03.09

DOC. NO. KOC-MP-033 PART 1 (SUPERSEDES KOC- M- 012, REV. 2)

ISSUING AUTHORITY:

STANDARDS TEAM

Issued as Final

KOC Standard Task Foroe 1111 A\A . .,:.A (J"F.MP/14) ~

Page 3 of 37 REV. 1 DOC. NO. KOC-MP-033 PART 1 r ~--------------------~----------------~---------------------

TABLE OF CONTENTS

FOREWORD

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

SCOPE

APPLICATION

TERMINOLOGY 3.1 Definitions 3.2 Abbreviations

REFERENCE STANDARDS, CODES AND SPECIFICATIONS 4.1 Conflicts 4.2 List of Standards and Codes

ENVIRONMENTAL CONDITIONS

HEALTH, SAFETY AND ENVIRONMENT

TECHNICAL REQUIREMENTS 7.1 Valve Design/Engineering 7.2 Valve Body 7.3 Anti-Static Design 7.4 Valve Operation 7.5 Anti Blow-Out Stem

VALVE MATERIALS 8.1 Valve Body and Other Components 8.2 Valve Identification Plate 8.3 Valve Seals 8.4 Threaded Opening in Valve Body for Plugs 8.5 Carbon Contents of Welded Parts of Valve 8.6 Electroless Nickel Plating (ENP) 8.7 Flanged Ends of Ball Valves

INSPECTION ANI) TESTING 9.1 General Requirements 9.2 Shop Inspection 9.3 Foundry Qualification 9.4 Quality Plan 9.5 Vendor Pre-Inspection Meetings (VPIM) 9.6 Hydrostatic Testing

Page No.

5

6

6

7 7 8

9. 9 9

12

12

13 13 14 15 15 16

16 16 16 16 17 17 17 17

18 18 18 19 19 20 20

DOC. NO. KOC-MP-033 PART 1 Page4of37 REV. 1

9.7 Valve Closure or Tightness Test 21 9.8 Nondestructive Examination 21 9i9 Hardness Testing 23 9.10 Examination Required-Socket Welding-end Valves 24 9.11 Positive Material Identification (PMI) 24

10.0 VALVE IDENTIFICATION

11.0 HANDLING, STORAGE AND CARE 11.1 Valve Handling 11.2 Valve Storage and Care

12.0 GUARANTEE & WARRANTY 12.1 Material, Valve Parts, and Valve Assembly

13.0 QUALITY ASSURANCE

14:0 -'-'-PACKING,-MARKTNGAN1YOOCLJME~TATfON'--------

15.0 DOCUMENTATION 15.1 General 15,2 Deliverables

16.0 SPARE PARTS AND MAINTENANCE DATA

APPENDICES:

",--' ~.~-.. , -

APPENDIX-I ILLUSTRATION SHOWING TYPICAL API 60 TYPE "DOUBLE ISOLATION-BLEED"

, (DIB) VALVE

APPENDIX-II KOC DATA SHEET FOR BALL VALVES

APPENDIX-III INDICATIVE INSPECTION & TEST PLAN FOR BALL VALVES

APPENDIX-IV RECOMMENDED MATERIAL FOR BALL VALVE COMPONENTS - ACCORDING TO FLUID/SERVICE

ACKNOWLEDGEMENT

24

25 25 25

25 25

26

26

26 26 27

27

28·35

28

29-30

31-33

34-35

36

D V

DOC. NO. KOC-MP-033 PART 1 Page 50f37 REV. 1

FOREWORD

This document "KOC Standard for Valves Part 1: Ball Valves (KOC-MP-033 Part 1)" is intended to provide basic technical requirements for Design, Materials, and Inspection & Testing of Ball Valves intended for GC's, BS's, Tank farm, Water Injection Plants, Pipelines, and other KOC onshore plants and facilities.

The Part 1 of this series of document (KOC-MP-033) covers "Ball Valves". Other types such as gate, globe, check and butterfly valves are covered in subsequent Parts under the same document number. This KOC Standard supplements the requirements of API 60 IIS014313, ASME B16.34, ISO 17292, MSS SP-72, and MSS SP-11 0 as applicable.

This Standard has been approved by the Standards Team, in consultation with the Standards Technical Committee (STC) for consistent use throughout the corporate engineering and operational facilities of Kuwait Oil Comp~ny.

This Standard sets out to achieve the following objectives:

)- To specify the minimum technical requirements for Design, Material of Construction-of- Ball-Valves- that-has- vast- and- significant application in KOC facilities and installations, with a view to achieve quality, reliability, efficiency & performance with cost effective approach.

)- To establish the necessary aspects of Inspection and Testing reqUirements of Ball Valves so as to minimize the need for technical clarifications and disputes.

)- To maintain the KOC requirements of safety, protection, and integrity of KOC piping, plant & equipment, personnel and environment as established by KOC Fire and Safety Regulations, and Health, Safety and Environment Management System (HSEMS) and HSE Policy.

)0 To augment comprehensively all aspects of design, construction, and testing necessarily required by Kuwait Oil Company.

Feedback, comments or suggestions, derived from the application of this Standard at any stage of design, construction, selection, purchase, field installation. operation, and maintenance are encouraged, and should be directed to:

,

The Team Leader Standards (Chairman, Standards Technical Committee) Industrial Services Group, KOC P. O. Box 9758, Ahmadi 61008, State of Kuwait

Task Force Responsible for This Standard

The Standards Technical Committee (STC) has entrusted the preparation of this Standard to the Task Force No. (TF-MP/14) conSisting of the following:

Mr. Mohsin Mirza Mr. H. Reddy Mr. K. Subramanian Mr. Ashish Kumar

Standards Team I & C Team (N&W) I & C Team (S&E) Design Team

TF Leader & Author Member Member Member

Ex: 61371 Ex: 61479 Ex: 61574 Ex: 61768

r /"',.


1.0 SCOPE

1.1 This standard specifies the basic technical requirements for "Design. Material, Manufacture, Inspection, Testing, and Marking of Ball Valves for use throughout KOC facilities and installations.

1.2 Ball Valve sizes, class, material and applicable standard(s) are as follows:

S. No.

1.

VALVE SIZE CLASS

# 150

NPS % to NPS 1 % # 300 #600

(See Note-I, & 2) #800 #900 # 1500 #2500

MATERIAL

CS, ASS, OSS, Ni-Alloy & High-Alloyed ASS

Bronze

# 150 CS, ASS, OSS, Ni-Alloy

APPLICABLE STANDARD

(See Note· 3)

BS EN ISO 17292

MSSSP 110

API 60 IIS014313 # 300 & High-Alloyed ASS ---- -- - -----2 ----. --- NeS_2and _OveL __ --_,. 60Q ---- I---=~=~ .. ~. -=--===---=---~-+=~-=--= .... ~-=--~~~-I---

. (See Note-I, & 2) # 900

Note-I:

# 1500 #2500

Ni-AI-Bronze ASME B 16.34

For selection of appropriate valve-ends (socket/threaded/flanged ends) refer to Piping Material Classes o lS-LH-I 00 1. However KOC Standard for Piping Material Classes KOC-MP-O lOis under preparation and will supersede/replace OlS-LH-IOOI when published. In the meantime, however 01 5-LH-100 1 will remain active/effective.

Note-2: Class 800 valves covered here are socket welded I threaded type only and of reduced bore.

Note-3: BaH valves intended for potable water service shall be in accordance with Standard A WW A C507.

1.3 Project.Specific requirements not covered in this Standard shall be specified by the controlling/concerned KOC Team in the Data sheet or Purchase Order and/or Contract SpeCification, as applicable.

2.0 APPLICATION

2.1 Ball valves should not be used where the fluid/service is entrained with sand particles.

2.2 These valves can be used in plant piping, pipelines, pressure vessels, heat exchangers, storage tanks, rotating equipment and other stationary equipment intended for process and utility services such as sweet and sour hydrocarbons (oil/condensate/gas), plant air, instrument air, non-potable water such as fire water, brackish water, produced water, effluent water etc. and compatible chemicals as applicable.

)y

DOC. NO. KOC-MP-033 PART 1 Page 7 of 37 I REV. 1

2.3 Any exceptions or deviations from this Standard, along with their merits and justifications, shall be brought to the attention of KOC Controlling Team for their review, consideration and amendment by Standards Team (if required).

2.4 Compliance with this standard does not in itself confer immunity from legal or statutory obligations.

2.5 Valve actuators are not covered in this standard. Actuators, if provided, shall be in accordance with KOC Standard for Motor Operated Valve Actuators KOC-E-013.

3.0 TERMINOLOGY

3.1 Definitions

For the purpose of this Standard the following definitions shall apply.

3.1.1 Anti-static design:

Design pI'I(Cllv~s_ such that it ensures electrical continuity throughout t_he valve body. ball and its stem.' -

3.1.2 Company:

The Kuwait Oil Company

3.1.3 Controlling Team:

Any KOC Team authorized to initiate a request for procurement of material and/or equipment for a KOC project, or any KOC Team that manages and/or controls and/or executes a KOC project.

·3.1.4 Double-Block- and-Bleed-Valve (DBB)

Single valve with two seating surfaces that, in the closed position, provides a seal against pressure from both ends of the valve with a means of venting/bleeding the cavity between the seating surfaces. (Refer to ISO 14313) .

. 3.1.5 Double-Isolation-and-Bleed-Valve (DIB)

Single valve with two 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. Refer to ISO 14313. (For sketch/details see Appendix-I of this Standard).

3.1.6 Non-Sour Service or General Service:

The service involving water such as potable water, brackish water, fire water, plant air, Instrument air etc. except the hydrocarbons, and fluids / chemicals that contain H2S, Chlorides and other acidic properties. It should be noted that waste / effluent water, in case has H2S, then, it should not be considered as general service.


3.1.7 Progressive Examination:

In case of random examination, when repairs are found necessary as a result of specific examination, then two additional items shall be examined. If either of these proves to be defective, all similar items shall have to be examined.

3.1.8 Sour Service:

The fluid. services or exposure to oil field environment that contain hydrogen sulphide (H2S) and that can cause cracking of materials (HIC / HSC / SCC/ SOHIC / SWC / SSC / SZC etc.) by some complex mechanism if the materials used are not in accordance with NACE MR0175/1S015156.

3.1.9 Valve Body:

The valve body is the "shell" that holds the service/fluid pressure, with ends intended for connection to piping /equipment. The valve body does not include components such as the ball, seats, seals and other internal parts of the valve that come in contract with the service fluid .

. -.--~---.-.--.--~.-- -------.----~--.-.- ... -.. -- -...

3.1.10 Valve Trim:

The functional parts of a valve .that are exposed to the line fluid, usually refer to the stem, closure member, and seating surfaces.

3.2 Abbreviations

ASS CS DSS DBB DIB HIC HSC HR HSE HSEIMS HSEMS KOC MAWP MOP NPS OSHA SCC SOHle SSC SWC SZC

Austenitic Stainless Steel Carbon Steel Duplex Stainless Steel Double-Block-and-Bleed Double-Isolation-and-Bleed-Valve Hydrogen Induced Cracking Hydrogen Stress Cracking Rockwell Hardness Health, Safety and Environment Health, Safety & Environment Integrity Management System Health, Safety & Environment Management System Kuwait Oil Company Maximum Allowable Working Pressure Maximum Operating Pressure Nominal Pipe Size Occupational Safety and Health Administration Stress Corrosion Cracking Stress Oriented Hydrogen Induced Cracking Sulfide Stress Cracking Stepwise Cracking Soft Zone Cracking

DOC. NO. KOC-MP-033 PART 1 I Page 9 of 37 REV. 1

4.0 REFERENCE STANDARDS, CODES AND SPECIFICATIONS

4.1 Conflicts

In the event of a conflict between this Standard and other KOC Standards or applicable codes referenced herein, or purchase or contractual requirements, or data sheets, the KOC (company) shall be notified of that deviation for a resolution. However the order of precedence in the case of a conflict shall be generally as follows without prejudice to the Contractual Order of Precedence

a) Kuwait Govt. Rules b) Data Sheet and project specific contractual requirements c) This KOC standard (KOC-MP-033 Part 1) d) Other KOC standards (Which in the opinion of the Superintendent of the

Project/Contract are relevant to this Standard.) e) Applicable international codes or standards

4.2 List of Standards and Codes

The--'atesTeditlon-(afthe-time of signing the -contract) of the following standards, codes and specifications shall apply:

4.2.1 National/International Standards

API6D /ISO 14313

API SPEC6FA

API 607 /IS010497-5

ASME 81.20.1

ASME 816.5

ASME 816.10

ASME 816.24

ASME 816.34

ASME 816.47

ASME 831.3

Petroleum and Natural Gas Industries-Pipeline Transportation System-pipeline Valves

Specification for fire Test for Valves

Testing of Valves - Fire Type - Testing Requirements

Pipe Threads, General Purpose (Inch)

Pipe Flanges and Flanged Fittings NPS % Through NPS 24

Face-to-Face and End-to-End dimensions of valves

Cast Copper Alloy Pipe Flanges and Flanged Fittings

Valves - Flanged, Threaded and Welding End

Large Diameter Steel Flanges NPS 26 Through NPS60

Process Piping

DOC. NO. KOC-MP.o33 PART 1

ASME 831.4

ASME B31.8

ASME B36.10

ASTM A105/A 105M

ASTM A182

ASTM A193

ASTM A194

ASTM A216/A216M

ASTM A 388/A 388M

ASTM B61

ASTM 8148

AWlVAC507

BS EN ISO 10497

BS EN ISO 17292

ISO 7

ISO 261

Page 10 of 37 REV. 1

Pipeline Transportation Systems for Liquid Hydrocarbons and other Liquids

Gas Transmission and Distribution Piping Systems

Welded and Seamless Wrought Steel Pipe

Standard Specification for Carbon Steel Forgings for Piping Applications

Standard Specification for Forged or Rolled Alloy and Stainless Steel Pipe Flanges, Forged Fittings and Valves and Parts for HighTemperature Service

Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for high Temperature or High Pressure Service and Other Special Purpose Applications. _

Standard Specification for Carbon and Alloy Steel Nuts for Bolts for high Pressure or High Temperature Service, or Both

Standard Specification for Steel Castings, Carbon, Suitable for Fusion Welding, for HighTemperature Service

Standard practice for ultrasonic examination of heavy steel forgings

Standard SpeCification for Steam or Valve Bronze Castings

Standard Specification for Aluminum-Bronze Sand Castings

Ball Valves 6 in. Through 48 in. (150 mm through 1200 mm)

Testing of valves-Fire type-testing reqUirements

Metal Ball Valves for Petroleum, Petrochemical and Allied Industries

Pipe threads Where Pressure-Tight Joints are made on the threads - Part 1 & 2

ISO General Purpose Metric Screw threads

DOC. NO. KOC~MP~033 PART 1

ISO 9000

ISO 9001

MSS SP-55

MSS SP-72

MSS SP-110

Page 11 of 37 REV. 1

Quality Management Systems - Fundamentals and Vocabulary

Quality Management Systems - Requirements

Quality Standard for Steel Castings for Valves, Flanges, Fittings and Other Piping ComponentsVisual method for Evaluation of Surface Irregularities

Ball Valves with Flanged or Butt-Welding Ends for General Service

Ball Valves Threaded, Socket-Welding, Solder joint, Grooved and Flared Ends

NACE-MR0175/IS0 15156 Petroleum and Natural Gas Industries-Materials Parts 1-3 for Use in H2S-Containing Environments in Oil

and Gas production

4.2.2 KOC Standards

KOC-E-013

KOC-G-004

KOC-Q-014

KOC I HSE Document

KOC Standard for Motor Operated Valve Actuators

KOC Standard for Packing. Marking and Documentation

KOC Standard for Project QA/QC Requirements

KOC Fire and Safety Regulations

4.2.3 015 Engineering Group Specifications

015-LH-1001

015-WH-1003

Piping Material Classes (See Note-l o/Clause 1.2)

Inspection of Castings for General Pressure Service


5.0 ENVIRONMENTAL CONDITIONS

The environmental conditions in Kuwait are severe. Refer to "KOC Standard for Basic Design Data" (KOC-G-007), which provides the basic information required for design such as the temperature, wind, environmental, site and utility supply conditions prevailing throughout the KOC facilities.

6.0 HEALTH. SAFETY AND ENVIRONMENT

All applicable safety requirements of Occupational Safety and Health Administration-OSHA Standards shall be considered in the design, materials, and manufacture of valve seals/gaskets covered in this standard. KOC prohibits use of asbestos in its facilities and installations.

The Manufacturer/Contractor shall fully adhere to KOC Fire and Safety Regulations, KOC HSEMS (HSE Management Systems) requirements, and KOC HSEIMS (HSE Integrated Management Systems) requirements/ procedures/guidelines for protection of KOC personnel, equipment, property, and environment etc where applicable.

DOC. NO. KOC-MP~033 PART 1 I Page 13 of 37 I REV. 1

7.0 TECHNICAL REQUIREMENTS

7.1 Valve Design/Engineering

7.1.1 Ball Valves shall be designed, manufactured, tested, and supplied in accordance with clause 1.2 of this standard.

7.1.2 The type of valves shall be in accordance with the reqUirements of KOC Data Sheets / Contract Specifications.

7.1.3 Unless otherwise specified in KOC Data Sheets/Contract SpeCifications the ball valves furnished shall be of full bore and suitable for pigging when applicable, except for class BOO valves (socket weld ends or threaded ends) as per BS EN ISO 17292.

7.1.4 Unless otherwise specified in KOC Standard for Piping Material Classes KOCMP-010/015-LH-1001 (See Note-1 clause 1.2), KOC Data Sheets / Contract SpeCification, the valve ends shall be as follows:

a) NPS % to NPS 1 %: Socket weld ends or Threaded ends or Flanged ends.

b) NPS 2 and above: Flanged with RF ends conforming to ASME B 16.5 or AMSE B 16.47 for class 150, 300, and 600, as applicable.

c) NPS 2 and above: Flanged with RT J ends conforming to ASME B 16.5 or ASME B 16.47 for Class 900,1500, and 2500, as applicable.

7.1.5 The face-to-face and end-to-end dimensions of ball valves shall be as per the applicable standard. However if the same is not specified in applicable valve standard or KOC Data sheets, it shall be as per ASME 816.10.

7.1.6 Ball valves shall be either floating type or trunnion mounted for sizes NPS % to NPS 3. However the ball valve sizes NPS 4 and over shall be trunnion mounted as per applicable standard specified in Clause 1.2 of this Standard.

7.1.7 All valves above size NPS 2 shall be provided with greasing nipples as mentioned below:

a) Drive/rotating mechanism and bonnet areas.

b) Seat holder area at each seat assembly (one grease nipple for sizes NPS 3 to NPS 6 and two grease nipples for sizes above NPS 6).

7.1.B The ball valve sizes NPS 2 and over shall be provided with necessary openings (threaded holes) for drain/vent connections. The connection shall be in accordance with API6D /IS014313/ASME B 16.34.

7.1.9 All valves sizes NPS 4 and above shall be provided with double block and bleed (DBB) arrangement to check the valve integrity against leakage/passing, when the valve is in closed condition. The blee~ ~


connections shall be fitted with threaded plugs preferably of NPS % on the top of the valve body for gas service and at bottom for liquid service. The threaded plug material shall satisfy NACE MR0175/IS015156 requirements.

7.1.10 In case the socket welded valves incorporate soft seats, the Manufacturer Nendor shall supply those valves complete with pipe nipples (at least 150 mm long) welded at each end of valve prior to valve assembly.

7.1.11 The ball valves shall conform to API 607 or ISO 10497 or API 6FA for FireTest Design.

7.1.12 The lever/wrench and bonnet-cover shall be provided on all valves with indicator to show the position of the ball port. Travel stops shall be provided for both fully open and fully closed positions of the valve.

7.1.13 The ball valves intended for potable water service shall be in accordance with Standard A\J\NVA C 507.

7.1.14 When the ball valves are intended for Double-Block-and-Bleed (DBB) or ... DQuble~I~0Ialioo~and-Blee.d.([)!J3.).Pll!P_0.S~~J.Jb~Jl1~nufl:lctur~L.~DaIL_ensure that such valves adequately satisfy the requirements as defined under clause 3.0 of this Standard/API6D/IS014313 or otherwise as required by KOC.

7.2 Valve Body

7.2.1 The minimum body wall thickness shall be as specified in applicable standard. In case of valves manufactured according to API 6DIISO 14313, the minimum body wall thickness shall conform to ASME B16.34 requirements.

7.2.2 Body seat ring assemblies shall be designed so as to be replaceable except for those valves having a one piece welded construction. Spring loaded seat rings shall be provided for sizes NPS 3 and above except in single $eat design. '

7.2.3 The valve seats shall be either metallic or non-metallic (or with elastomer insert) as per the KOC Data Sheet. Refer Appendix-IV of this Standard.

7.2.4 In case of valve with metallic seat, a minimum hardness differential of 50. HB shall be provided between ball and seat surface.

7.2.5 In case elastomer insert is used, seat shall be fabricated in such a way as to ensure proper seal in case of damage or wear of elastomer material. Secondary sealing arrangement shall be provided for sizes NPS 4 and above by means of a sealant filling port through which sealant can be injected. Single seat designs need no secondary sealing arrangement.

7.2.6 In case of valves manufactured to MSS SP-11 0, the Manufacturer shall submit the design calculations in accordance with ASME Sec. VIII Div. 1 for Company approval.

7.2.7 All valves shall be provided with lock-openllock-closed provision.


7.2.8 The ball valves shall be tight shut-off and closure tightness test shall be "as per the applicable standard specified in Clause 1.2 of this Standard.

7.2.9 The adjustable packing glands of valves shall be easily accessible for tightening the stem seals without disassembling either the valve itself or its parts.

7.3 Anti-Static Design

7.3.1 Soft seated valves shall be provided with anti-static device to ensure electrical continuity between ball, stem and valve body. Anti-static devices are not necessarily required in valves designed for metal to metal contact provided that the level of contact resistance does not exceed 10 ohm (on dry valve) under any operating condition, using a 12 volt D.C. power source.

7.3.2 The Manufacturer shall submit to KOC an authentic and valid certificate showing conformance and compliance with the above requirement.

7.4 Valve Operation

The valve manufacturer shall submit a duly completed data sheet conSidering all the requirements of contract specifications and KOC Data Sheet for KOC (company) review and approval. An indicative Data Sheet format is shown in APPENDIX-II of this Standard. The ball valve operation mechanism shall be as shown in the Table-1 below:

Table-1: VALVE OPERATION

2 600

3 900,1500 and 2500 3 (Inclusive) Over

Note-I: All actuated ball valves shall have an alternate mechanism to operate manually.


7.5 Anti-Blow-Out Stem

7.5.1 The valves shall be designed to ensure that during operation if a failure occurs either at stem-ball connection, or at any other part of the stem within the pressure boundary then no portion of the stem shall be ejected out.

7.5.2 The design shall ensure that while under operation, the valve stem shall not eject when the valve external parts such as gland and gland flange bolting are disassembled.

8.0 VALVE MATERIALS

All Materials used in the valves shall be brand new and of prime quality conforming to the requirements of this Standard and the codes, standards, and specifications referenced herein.

8.1 Valve Body and Other Componenl§

8.1._1_~he s~l~ctioll QLappropriate material for various components of ball valve shall be in accordance with the KOC Data Sheets / Contract Specifications, KOC Standard for Piping Material Classes KOC-MP-010/015-LH-1001 (See Note-1 of Clause 1.2) and Appendix-IV of this Standard.

8.1.2 In addition, the materials of valves intended for sour service shall conform to the requirements of NACE MR0175/ISO 15156.

8.1.3 The Manufacturer shall strictly conform to the materials as specified in the KOC Data Sheet. Manufacturer shall ensure that ASTM A-36 or any other structural quality material shall not be used for any part(s) of the valve(s).

8.2

8.3

Valve Identification Plate

The material used for the identification plate shall be an austenitic stainless steel or a nickel alloy. The identification plate shall be attached· to the valve by corrosion-resistant rivets.

Valve Seals

8.3.1 In case the stem seals, body seals, cover seals etc are non-metallic they shall be suitable for the maximum design/allowable temperature, whichever is higher, of the system.

8.3.2 Stem seals shall be such that they can be replaced while the valve is onstream for valves with block-and -bleed arrangement.

8.3.3 Provision shall be made for emergency stem sealing injection for valves size NPS 4 and over. This arrangement shall be provided to restore the sealing integrity if damage is caused to the sealing surface(s).


8.4 Threaded Opening in Valve Body for Plugs

8.4.1 Where the threaded plugs are intended in sour service, it shall be bleeding type for safe release of leaked fluids to prevent any accidental damage to the operator or as otherwise required by KOC.

8.4.2 When the valve is intended for sour service, the plug material shall meet the requirements of NACE MROl75 /18015156. Normally threaded plugs are not recommended in sour service, therefore the Manufacturer/Contractor should suggest/propose a suitable alternative to KOC.

8.4.3 Malleable, grey or any other form of cast iron shall not be used for plugs.

8.5 Carbon Contents of Welded Parts of Valve

8.5.1 The carbon and manganese contents of all pressure-containing parts for carbon steel materials involved in welding operations shall be restricted as follows:

_. -' --',

a) C = 0.25 % (Max)

b) The Carbon Equivalent (CE) shall be 0.41 % max as specified below: CE = C% + Mn%/6 +(Cr%+Mo%+V%)/5+(Ni%+Cu%)/15 = 0.41 % max.

8.5.2 For the alloy steels and stainless steels materials involved in welding, the carbon content shall be limited to such a level to ensure good weldability.

8.6 Electro'ess Nickel Plating (ENP)

8.6.1 The carbon steel balls (for applicable sizes refer Note-1 of Appendix-II) shall be plated with Electroless Nickel Plating (ENP) in accordance with ASTM B 733 8C 4, severe service, Type II or III phosphorus contents, and heat treated to Class 1 or 2 as per A8TM B 733.

8.6.2 The ENP composition shall be: 10-12 % Phosphorus, 0.05% of unspecified elements (max) and remainder as Nickel.

8.6.3 The ENP thickness shall be 76 jJm (min.)

8.6.4 The ENP shall be tested for the following: Appearance, Thickness, Adhesion, Porosity (Ferroxyl Test). Hardness, Alloy composition, and Corrosion resistance.

8.7 Flanged Ends of Ball Valves

8.7.1 Flanges of the flanged type ball valve size NP8 24 and under shall be as per ASME B 16.5. and for size 26 and over shall be as per ASME B 16.47 series 'A' Type, unless otherwise specified/required by KOC.


9.0 INSPECTION AND TESTING

9.1 General Requirements

9.1.1 The manufacturer shall carry out inspection and testing as specified in this Standard and in accordance with Company Approved inspection and Test Plan (ITP).

9.1.2 The construction, quality of workmanship, the dimensions, inspection and testing of ball valve shall be carried out in accordance with API 6D 118014313 or BS EN ISO 17292 or MSS SP-110 as applicable and this KOC Standard.

9.1.3 The testing of valve materials shall be carried out by the Manufacturer at his own laboratories or at a laboratory internationally recognized and duly accredited to international Standards.

9.1.4 The test certificate for fire safe design as per the applicable standard shall be submitted to KOC for review and approval.

9.1.5 Manufacturing, Inspection & Testing of valves shall take place at KOCis approved Manufacturer's facilities only.

9.1.6 Contractor or its authorized inspection agency shall inspect the materials in accordance with the Inspection and Test Plans (ITP) prepared by the Manufacturer and approved by the Company.

9.1.7 In addition, Company reserves the right to carry out the inspection (on its own or appoint a third party to do so on its behalf or both) and examination of the valves at the manufacturing facilities and testing laboratories in accordance with the Company approved ITP.

9.1.8 All bought-out items (such as castings, forgings etc.) shall be inspected at the sub-vendor's premises by the valve Manufacturer.

9.1.9 When random inspection is specified and if it fails to meet the requirements, progressive inspection shall be carried out to the satisfaction of Company at the cost of the manufacturer.

9.2 Shop Inspection

9.2.1 The manufacturer shall be responsible for all required QA/QC and inspection work to satisfy the requirements of this Standard.

9.2.2 KOC may utilize the services of his inspectors or inspectors appointed by him (KOC) to visit the Manufacturer's facilities to witness and verify the quality of work, raw materials, finished products, production process and the equipment used.


9.2.3 The KOC or inspectors appointed by KOC shall have free access to those areas of the Manufacturer's facilities that are necessary to ensure that the manufactured products comply with the requirements of this Standard and the Standards referenced herein.

9.2.4 KOC (Company) inspectors shall have a minimum of two (2) weeks advance notice, and shall be provided access to the Manufacturers shop(s) during manufacturing, fabrication, assembly, inspection and testing of all components I items of supplies covered by this standard.

9.3 Foundry Qualification

9.3.1 The foundry shop shall be fully accredited to ISO 9000 quality systems and shall be amply capable to handle the size and weight of the required forgings or castings.

9.3.2 When large order is placed the first pouring qualification shall be carried out for each size and type of valve in presence of Company or its nominated ag~nc::ies._____ ____________________ . _______________ . _________ . ___ _

9.3.3 If the first pouring is approved and qualified then further qualification of the pouring shall not be required for other purchases from the same manufacturer for the sizes and types of valves qualified.

9.3.4 The following are mandatory requirements for first pouring qualification:

- Chemical Composition - Mechanical Properties - Visual and dimensional inspection - 100% RT shall be performed. - 100 % MT I PT shall be performed accordingly - Hardness Survey

9.4 Quality Plan

The valve Manufacturer shall prepare and submit a detailed quality plan for Company approval. The quality plan shall consist of the following:

9.4.1 Manufacturing Plan

9.4.2 Inspection and Test Plan (lTP)

a) The Manufacturer shall prepare ITP in accordance with manufacturing plan as per the contractual requirements and shall submit to Company for approval.

b) Tentatively the ITP shall list the sequence of all inspection and testing activities that shall be carried out by the Manufacturer, Contractor and Company or their appointed third party inspection agencies. The plan shall include manufacturing, fabrication, assembly, inspection and testing and packing for shipment in a chronological order. showing the frequency p


9.4.3

9.4.4

9.4.5

9.4.6

9.5

9.5.1

9.5.2

9.5.3

9.6

of control, the acceptance limits, the governing code and whether a document or report is produced for each activity.

c) An indicative ITP is attached in APPENDIX-III of this Standard for guidance only to facilitate the Manufacturer about the outline of ITP inspection activities. However, the extent of examination by Company & Contractor shall be finalized on mutual agreement.

Inspection & Test Procedures

Valve Detailed drawings & Data Sheets

List of sub-vendors

Manufacturer's QA/QC organization chart

Vendor Pre-Inspection Meetings (VPIM)

The VPIM shall be conducted at Manufacturer's facility as per Company Co"-tract Specification requirements.

The agenda for the VPIM shall be in accordance with the Company Contract SpeCification / Company purchase order requirement and KOC-Q-014.

During the VPIM the vendor, contractor and company will review and finalize the ITP and confirm the requirements for witnessing 0JV), surveillance (S), monitoring (M), and reviewing (R) in the plan. The approved ITP shall be strictly adhered to throughout the entire fabrication, assembly, inspection, and testing period'; •

Hydrostatic Testing

Note: Test Certificates for each valve successfully passing the shell tests shall be provided by Manufacturer/Contractor to KOC, documenting compliance of tested valves with test requirements, including test pressure. Moreover when the hydrostatic testing of new or existing piping or pipeline systems containing ball valves is undertaken, it shall be ensured that all ball valves are in the fullopen position and the line test pressure shall not exceed the allowable hydrostatic test pressure of valve body or shell.

9.6.1 General Requirements:

a)

b)

c)

The test fluid temperature shall be within the temperature range of 5 °c and 50°C.

In case of carbon steel valves the test shall be carried out with fresh water that may contain corrosion inhibitor, or with kerosene, or with other suitable fluids provided the viscosity of such fluids is not greater than that of water.

In case of stainless steel valves, the test shall be carried out with water that shall not contain chlorides exceeding 30 ppm. ~

/'


9.6.2 Valves shall not be painted or otherwise coated with materials capable of sealing against leakage before the valve body tests.

9.6.3 All gauges shall have a range such that the test pressure is within 30% to SO% of the full range. The gauges shall have valid calibration certificate.

9.6.4 Body Hydrostatic Test

The body hydrostatic test shall be carried out in accordance with the applicable valve standard.

9.7 Valve Closure or Tightness Test

9.7.1 The valve closure test shall be done in accordance with the applicable standard.

9.7.2 In addition, low pressure closure test (supplementary test) shall be carried out for valves conforming to API 60 liSa 14313. The low pressure closure test shall beat a pressure 5.~.bar± 0.7 bar.

9.8 Nondestructive Examination

9.S.1 Visual Examination

All valves shall be visually examined in accordance with MSS SP-55.

9.S.2 Valve Surface Examination

a) All exterior and all accessible interior surfaces of valve body and bonnet shall undergo a surface examination.

b) Technique:

i) Magnetic Particle Testing shall used for all Ferromagnetic materials as per ASME Sec V, Article 7.

ii) Penetrant Testing shall be done on all non-magnetic materials as per ASME Sec V, Article 6.

c) Extent of Examination

100% Examination on all valves intended to be used in sour service. 100% Examination on all valves of Class 600 and over intended to be used in non-sour service.

d) Acceptance Criteria

i) Acceptance criteria for of PT shall be in accordance with ASME Sec VIII, Div 1, Appendix-S.

/'

DOC. NO. KOC·MP-033 PART 1 Page 22 of 37 I REV. 1

Ii) Acceptance criteria for MT shall be in accordance with ASME Sec VIII, Oiv. 1 Appendix-6.

9.8.3 Radiography Examination

I. Butt Welds:

a) Technique: RT (Radiographic Examination) as per ASME Sec V, Article 2.

b) Extent of Examination: All butt welds shall be 100% examined.

c) Acceptance Criteria: Radiographs shall be evaluated as per UW-51 of ASME Sec. VIII Div.1.

II. Cast Valves (Body and Bonnet):

a) Technique: Examination of casting intended for valves shall be carried out in accordance- -with-ASME Sec V, Article· 2 and as specified in supplementary NOE (Nondestructive Examination) requirement A.2 of API 60.

i) The Coverage and location of radiographic examination shall be as per ASME 816.34

Ii) UT in place of RT shall not be acceptable.

b) Extent of Examination:

a) All valves shall be 100% radiographed for sizes NPS 6 & above for class 600 & above.

b) For all other classes for size NPS 6 and above, the examination shall be on 20% of valves selected on random basis. The random selection shall include all sizes and classes of valves on production basis.

ii) Non-sour-service

10% of all valves selected on random basis shall be radiographed for valve size NPS 6 and over. The random selection shall include all sizes and classes of valves on production basis.

c) Acceptance Criteria:

i) ASME B16.34 Appendix I shall be used for acceptance criteria.

v


ii) In case of random examination, when repairs are found necessary as a result of radiographic examination, then progressive examination shall be followed.

9.8.4 Ultrasonic Examination of Forged Valves (Body and Bonnet):

a) Technique:

Examination of forgings intended for valves shall be carried out in accordance with ASME Sec V, Article 5 and ASTM A388.

b) Extent of Examination:

c)

i) Sour-service

a) All forged bodies prior to proof machining shall be 100% ultrasonically examined for sizes NPS 6 & above for class 600 & above.

b) For all other classes 'for size NPS 6 and above, tlie examination shall be on 20% of valves selected on random basis. The random selection shall include all sizes and classes of valves on production basis.

ii) Non-sour-service

10% of all valves. selected on random basis shall be 100% ultrasonically examined for valve size NPS 6 and over. The random selection shall include all sizes and classes of valves on production basis.

Acceptance Criteria:

i) Acceptance criteria shall be in accordance with Appendix IV-2.1 of ASME B 16.34.

ii) In case of random examination, when repairs are found necessary as a result of radiographic/ultrasonic examination, then progressive examination shall be followed.

9.8.5 Defect Removal and Repair

i) Defect removal and repair shall meet the requirements of ASME B16.34 Para 8.4.

ii) In case of castings, KOC specification 015-WH-1003 shall also apply. iii) PWHT is mandatory for Ferritic steels intended for sour service.

9.9 Hardness Testing

9.9.1 All wetted parts of valves (and repair welds) intended for sour service shall be hardness tested in accordance with NACE MR017511S015156.


9.9.2 Hardness Test shall be done on 10% of valves per heat selected on random basis. The random selection shall include all sizes and classes of valves on production basis. Valves not meeting the hardness requirements shall be rejected and progressive examination shall be followed for the entire heat.

9.9.3 If the Hardness Testing reveals any points not meeting requirements, additional testing shall be done as per the progressive examination.

9.10 Examination Required- Socket Welding-end Valves

9.10.1 This requirement is applicable to socket weld end valves to determine whether the socket size is appropriate. It is recommended that a max clearance /gap of 1.0 mm be provided.

9.10.2 Radiography shall be performed on random basis of 5% of socket welds to find out the clearance/gap between the pipe nipple and of socket.

9.10.3 When incorrect gaps are found, additional radiography is required as per the progresslve~)i(~miflJlti9n~ ___ .. ,. ___ ._ .. _~ .. _.. ._ .. _ .. ~._ _ __ ... _ ... _ ...

9.11 Positive Material Identification (PMI)

9.11.1 PMI shall be done on valves ma.de of corrosion resistant alloys. The extent of examination shall be 10% of valves selected on random basis. The random selection shall include all sizes and classes of valves on production basis. For other details refer API RP 578: Material Verification Program where required.

9.11.2 The PMI results shall meet the applicable material specifications.

9.11.3 During random PMI, if the examination results do not conform to the material specification, then progressive examination shall be followed.

10.0 VALVE IDENTIFICATION

10.1 Valve identification shall be in accordance with the applicable Standard.

10.2 In addition, the ball valves identification shall also fulfill the following requirements:

10.2.1 Unique serial number for each valve shall be mentioned in the body and the name plate of the valve.

10.2.2 Valve size and class shall be mentioned on the valve body by embossing or punching (with round nose punch) for valve sizes NPS 3 and above.

10.2.3 Details of ball and seat materials shall also be included in the name plate details.

10.2.4 Ball Valves intended for sour service shall be marked as "Comply NACE MR0175I1S015156".

DOC. NO. KOC·MP·033 PART 1 Page 25 of 37 REV. 1

11.0 HANDLING. STORAGE AND CARE

11.1 Valve Handling

11.1.1 As soon as the valve testing is successfully completed, the flanges of the flanged valves shall be covered with plywood or other protective devices (with bolts) to avoid ingress of moisture or any foreign material inside the valves.

11.1.2 The valves are precision machined and manufactured to achieve a smooth flange surface. It is therefore imperative and necessary that the valves should be handled with care in order to avoid any scratch or dent or damage to the flange surface.

11.1.3 It is recommended that the valves should be softly, carefully and correctly handled, packed and transported to avoid any unnecessary jolts, hit, bump and knock-down.

11.1.4

11.1.5

11.1.6

11.2

11.2.1

11.2.2

11.2.3

12.0

12.1

12.1.1

12.1.2

It should be ensured that the valve does not come in contact with any . chemical or fluidjnofder to avoid it from injurious effects and corrosion.

Ball valves, especially larger sizes, should be stored and shipped in the fullopen position to prevent damage to the exterior surface of the ball.

Lifting lugs shall be provided on all valves size NPS 4 and above.

Valve Storage and Care

The valves shall be stored carefully in a clean and dry environment.

The valves shall be protected with plastic end caps to prevent ingress of water, moisture, foreign material, dust, dirt etc and also to protect the flange faces.

It is recommended that the valves should be stored in covered area to prevent damaging effects of rain, dust, and weather.

GUARANTEE & WARRANTY

Material. Valve Parts. and Valve Assembly

Unless an exception is recorded by the Manufacturer I Supplier in his proposal and is agreed and accepted by KOC (Company), it shall be understood that the Manufacturer I Supplier agrees to the guarantee and warranties as per clause 12.1.2 of this Standard.

All valve and its components shall be new and the valve shall be warranted by the Manufacturer I Vendor I Contractor against defective and inferior quality material, design, workmanship and is fit-for-the-purpose in accordance with the requirements of Purchase order I Contract speCification.

DOC. NO. KOC~MP-033 PART 1 Page 26 of 37 REV. 1

12.1.3 The Manufacturer I Supplier shall provide to KOC (Company) an affidavit stating in clear terms that all supplied Ball Valves, its material, and its components etc. are in accordance with the requirements of this Standard and the codes and the standards referenced herein.

13.0 QUALITY ASSURANCE

The Manufacturer shall operate quality systems to ensure that the requirements of this Standard are achieved. The quality systems shall be based on ISO 9000 series of Standards or equivalent. The Manufacturer shall demonstrate compliance by providing a copy of the accredited Certificate and a copy their quality manual. Verification of Manufacturer's quality system is normally part of the pre-qualification procedure and is, therefore, not detailed in this Standard.

14.0 PACKING. MARKING ANI) DOCUMENTATION

14.1 Packing, marking, and shipping documentation shall comply with the requirements of KOC Standard for lIPacking, Marking and Documentation" (KOC-:-G-_004)J~nd aILs1~r1ctarct§r~fE!r~!l~ed_herein. ___________________ .

14.2 The marking shall be as follows or otherwise as required by KOC:

a) Manufacturer's name and Trade Mark

b) Valve Body Material

c)· Pressure Class, e.g. #150 or 300

d) Nominal Size e.g. NPS 12, or NPS 20

e) Valves that are intended for sour service shall be marked as "Comply NACE MR0175/1S015156"

f) Any other supplementary reqUirements, deemed necessary

15.0 DOCUMENTATION

15.1 General

15.1.1 All correspondence, instructions, Data Sheets, drawings, calculations, procedures or any other written information shall be in English language. In case of dual languages, one language shall be English.

15.1.2 All dimensions, units of measurement, physical constants etc. shall be in SI units, unless otherwise specified.

15.1.3 In addition to hard copies, all final documents such as speci'fications, Data Sheets, drawings, procedures and inspection reports shall be provided in electronic software formats (Latest versions of Microsoft Word, Excel, and AutoCAD).

i .


15.2 Deliverables

15.2.1 The Manufacturer shall submit to Company for review and approval the manufacturer's Record Book (MRB) with all certified valve test certificates, asbuilt data sheets, as-built General Arrangement & Assembly Drawings, procedures & inspection reports, spare parts details, Valve Brochures etc.

15.2.2 Valve unique serial number shall be mentioned in the valve test certificate.

16.0 SPARE PARTS & MAINTENANCE DATA

The Packager shall comply with the requirements of "KOC Standard for Spare Parts and Maintenance Data" (KOC-G-009).

v


APPENDIX-1

ILLUSTRATION SHOWING TYPICAL API 60 TYPE "DOUBLE- ISOLA TION-8LEED" (018) VALVE

Typioal API~SD Valve, Type - IIDI:B-1 11

Ve'nt Plug

\

\ \

DralnplUg~

<

DOC. NO. KOC·MP-033 PART 1 Page 29 of 37 REV. 1

APPENDIX·II

KOC DATA SHEET FOR BALL VALVES

DESIGN FEATURES: S.No DESCRIPTION I MANUFACTURER'S PROPOSAL

1 DESIGN CODE I 2 NOMINAL SIZE (Inch) i

3 VALVE TYPE

4 VALVE OPERATION MECHANISM

i 5 DOUBLE BLOCK AND BLEED YES 0 N/A 0 6 VALVE ClASS/RATING I 7 LOCK OPEN/LOCK CLOSED YES 0 N/A 0 8 ANTI BLOW-OUT STEM YES 0 N/A 0

SERVICE REQUIREMENTS:

9 SERVICE FLUID (LIQUID /GAS)

10 FLOW MEDIUM COMPOSITION

11 COMPLY NACE MR0175/IS015156 YES 0 N/A 0 12 CONTAMINANTS (IF ANY)

13 DESIGN / MAX. OPERATING PRESSURE

14 MAX DESIGN / OPERATING TEMPERATURE

15 MIN DESIGN / OPERATING TEMPERATURE

16 BODY MATERIAL DESIGNATION

17 SERVICE TEMP. Max ................. Min ...............

18 PRESSURE CLASS

19 MAX. DIFF. OPERATING PRESS ........................

20 BI-DIREC110NAL SHUTOFF YES 0 N/AO

21 MAX. OPERATING TORQUE (at max. differential pressure)

22 MAX. ALLOWABLE TORQUE - LIMITED BY STEM:

23 ALLOWABLE LEAKAGE RATE (Metal Seated Valves Only)

24 TYPE: DBB VALVE OR DIB VALVE YES 0 N/AO

CONSTRUCTION REQUIREMENTS: BS EN ISOl7292 0 API6D /150 14313 0 M5SSP-ll0 0 25 MSSSP-72 0 ASME B16.34 0 FIRE5AFE DESIGN: API607 0 API6FA 0 15010497 0 26 FIRESAFE TYPE TESTED & CERTIFIED: 0

27 NOMINAL SIZE:

i 28 FACE TO FACE DIMENSION:

I 29 END CONNECTIONS: i

30 CONSTRUCTION TYPE:

0 0 0 1-Piece 2-Piece 3-Piece

31 ENTRY TYPE: Side entry n Top entry n 32 BALL TYPE: (Solid / Sealed Cavity / Cored Cavity / Hollow)

33 BALL SUPPORT: FLOATING 0 TRUNNION 0 34 ANTI STATIC: YES [] N/A n

3S CAVITY RELIEF METHOD:

36 BORE TYPE: FULL BORE 0 REDUCED BORE 0

37 OPERATOR: WRENCH GEAR ACTUATOR

~ /' :I


38 ! PORT POSITION INDICATOR METHOD:

39 LOCKING DEVICE: YES 0 N/A 0 METHOD:

40 ANTI· BLOWOUT STEM:

41 EXTENDED BONNET YES [] N/A 0 42

SEALANT INJECTION: YES 0 N/A 0 MANUFACTURER'S RECOMMENDATION:

43 OTHER BODYTAPPINGS

44 FOUNDRY QUALIFICATION: YES U N/A U

MATERIAL REQUIREMENTS: 45 BODY CASTING OR FORGING SPEC/GRADE

46 NDE OF BODY CASTINGS

47 NDE OF RING GROOVES: I

48 PMI ON CORROSION RESISTANT ALLOYS: I 49 PURCHASER APPROVAL OF MAJOR CASTING REPAIRS: YES NO

50 STATE IF FLANGES OR BODY TO BE WELDED: i

51 CARBON/C.E. LIMITATION:

52 BALL MATERIAl.: I 53 ACCEPTABILITY OF PLATED BALL YES NO

54 SEAT MATERIAL: 0 5S HARD FACING: - .. _. -. METAlSEATS _. ·····0 BAll

--, .. 0 ..-.- ..

56 RENEWABLE SEAT RINGS YES NO

57 STEM MATERIAL:

58 TRU NNION BEARING MATERIAL AND PLATING IF ANY:

59 STEM SEAL

60 BODY SEAL GASKET 0 i

TEST REQUIREMENTS:

I 61 I TESTS REQUIRED AS PERTHIS STANDARD: I I

MARKING, COATING, PROTECTION & PACKING REQUIREMENTS: 62 COlOUR CODE

63 ITEM CODE(S) : , 64 EXTERNAL COATING/PROTECTION

65 INTERNAL COATI NG/PROTECTION

66 END PROTECTION

67 PACKING

.68 NAME PLATE FIXING

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:E ::I:I~ II II

:E::I: ~. 0 ,.,.. --::l 0-~ rJ>

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t~ ~--o ..... "'1 o 9 "'1 6:i 5'

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For Guidance Oni -Indicative Ins ecHon & Test Plan for Ball Valves Inspection and Test Plan Suggested/Indicative Inspection & Test Plan for Ball Valves Project No/ Contract No

Applicable KOC Specification: I<OC-MP·033 Part-1 Purchase order No: Sr. No. I Component or Process' Characterestics to be I Type of Check I Extent I Reference document/ I Format of TYPE OF INSPECTION

checked of Acceptance Standard Record

2

3

Document Review and approval

Vendor Pre.lnspection Meeting

Castings I Forgings:

Casting/ forging :n !qualification

( Body, Ball, Trunion, ,<;:ICover,Stem & Etc ... )

Review of PO I Data sheets / drawings,l Inspection & Test procedures nnd welding procdures.

Soundness of casting / Forging

Chemical composition & Mechanical properities

Heat treatment (HT)

Documellt review,

First Pouring i Forging witness

Review of material test reports.

Review of heattreatment chart

Check

100% KOC.MP-33.Pt.li & Contract specifica~on

requirements.! !

As per the Contrllc\ document '

Refer lAS per KOC stand,\rd Note-2 KOC-MP-33 Pt.l.

One per IAPPlicable Material heat Specification '

Each HT b~tch

Applicable Materia,l Specific,Hio!1

Radiography Testil1g Volumetric As per As per Cumpany

Document / ProcedlJrt'

Minutes of Meeting

Qualification Report

Valve Test Certificate

HT chart

Valve Mimufacture

H

H

H

H

I I I

1

1 J I Ii

• i (RT) for clItings & defects KOC- Approved RT / "A! t:ltTasonic Testing (L:T) MP.:n procedure I!

i for Forgings '1 i

RT i VT report

H

Contractor / its

nominated TPI

RJ r\

1-1

1-1

R

{,

R

I Penetrant Testing,' Surface defects As per A.s per Company PT / 111T I I . R "; 'I ;'vl;Jgnehc Particle Testing KOC- Approved I'T / M~ Report I H ;

I as '))11'\:(',)\11<:, ~1P-::'3 pro<:edtlre. I l_. - - I!

KOC/its nominated

TPI

R/A

II

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f,

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I' .,

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:I> "'0 "'0 m Z C >< :5

c o r> z p

a o • !5: "'0 o w w

~ ~ .....

~ U2 CD W ...1.

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Sr.:-.Io. Component or Process Characterestics to be Type of Check Extent Reference document I Format of TYPE OF INSPECTION A checked of Acceptance Standard Record 0

Check Contractor II .

(') I

Valve 3: Manufacture

its KOC/its "0 nominated nominated •

TPI TPI Q W W

Visual Inspection Visual As per As per KOC standard Visual H·for sub· "0 1.6

KOC- KOC·MP·33 Pt.1. fnspection Vendor & )0 MP·33 Record Valve

R R

~ manufacturer

Dimensional Inspection Measurement Asper As per KOC standard Dimension H-for sub-~

,~ KOC- KOC-Mp·33, Record Vendor & r--

• .1 MP-33 Valve

R R

manufacturer Positive material Verification of Applicable Material )?MJReport Identifica tion on chemical Specification and "0

:<.8 100% H }vlin 20% W Min 10% \'\' I)

Corrossion resistant composition Company approved (,Q

alloys or overlays, procdure, CD W

Hardness Test ( for Material test Applicable Material Valve Test N

valves under Sour report I Lab Specification and Certificate 0 .... 1",1 Sourvice) report. 40% NACE MR 0175/150 H Min 20% W ,\lin H)'Yo IV W

1 15156 & Company ..... approved procedure.

Fasteners uSllld [!ilr

.J I2ressure retainng -comRonents:

Chemical composition &: Material test One per Applicable Material Material Test ..j .1 Mechanical properities report, Heat Specification Certificate H R R

Hardness Test Material test As per

Applicable Material Material Test ! report / Lab Specification and Certificate,

·+:21 report. Material NACE MR 0175 IISO H :Vlin 20'1., I,V Min HiW. W

spec 15156. :;0

5 Final Insl1li:ctioD ~ Visual & Dimensional Visual&: As Per KOC standard Valve test ~ , Examination after final KOC·MP.33& -; Ii Dimensional 100% certificate H 'vlin ::2O~" \ \' \thn 1(~1!,} 'IV

0 . i assemblv Check. Approved vC\lve

drawings I

~ I

c 0 p Z

Sr. N0'1 Component or Process Characterestks to be Type of Check Extent Reference documentl Format of TYPE OF INSPECTION P checked of Acceptance Standard; Record A

Check I 0 I

I

Contractor II (") Valve I

Manufacture its KOCI its i: nominated nominat~d "0 r

TPI TPI • Q

Shell Hydrostatic testing Check for As Per KOC standard ! Valve test W W

5""f visible leakage 100%

KOC-MP-33 Pt. 1 & certificate H Min2ll%W Min l(l'.~n IN "0 ,~ Company approved I »

procedure. " Valve Closure test Check for As Per KOC standard I Valve test ~

visible leakage certifica te .....

3.3 100% KOC·MP·33 Pt.1 & I H Min :!O% W !I.'iiI110% W Company approved ,

procedure. Electical Continuity Anti-static As Per KOC standard i Test Report

:; .1\ between body, ball and design Type KOC·MP·33 Pt 1 & ; H W/R \\'/I~

stem test Company approved i "0 procedure. i IU

CO Surface preparation and Visual As per KOC standard I Painting CO

5.5 Painting on the valve examination & 100% KOC·P·OOl & Company Report Ii :-.·lil1 20% IV :-li1\ ](1'\ \" W OFT check approved procedure, : W

0 Documentation i ....

6 I w ! .....

Final Inspection Release Issue of release As Per KOC standard I Release note Ii,l note note 100% KOC·MP·33 Pt.1 i H H H

!

I . ~hipping Release note Release for As per Contract i Shipping , ,

. despatch 100% requirements. i Release H H R 0'._

! nnte Manufacturing Record Review of As per Company : MRB

6.,:\ Book Documents 100% approved MRS index i H H H

Note: (1) This suggested/Indicated Inspection &. Test Plan(ITP) is for guidance only. The ~anufacturer shall prepare the ITP based on manufacturing plan, Contractual requirements, as per the guidelines of this indicative ITP:and submit for Company approval.

" (2) At the start of production for each size and class. m i ITPNO. : :< . REV.NO. : .....

DATE :

(PREPARED BY) (CHECKED & APPROVED BY) ,...J.

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" Z RECOMMENDED MATERIAL FOR BALL VALVE COMeONENTS ACCORDING TO FLUID/SERviCe ~ 0

z " Sr.No. Fluid Handled Body,Bonnet Stem,Trunnlon Ball ~eat ~I,~~!~ote. Spring Body Studs,Nuts ~ ~

A1,93 B71A194,2H <: s: 1 PI t A' 0' I 'I L GI I CS: A105 or A216· 3165S ~165S(N t .1) RPTFE inconel X- With Electro-Zinc "p

an Ir, lese 01. ean yco WCB '" 0 e 750 Plating as per 0

• ASTM B633 ~

Bronze 661(UNS " Bronze B61(UNS C92200) upto l>

C92200) upto NPS 1 Y. Ni.AI Bronze 8148 NPS 1 Y. 8. Ni-AI Inconel X- ~ 2 Potable Water & NI·AI Bronze 8148 UNS C95800 Bronze B148 I! RPTFE 750 Copper Alloy ..

UNS C95800 above UN5 C95800 i! NPS 1Y. above NPS 1% :

I I Bronze B61 (UNS Bronze B61 (UNS : ; C92200) upto NP5 2 & C92200) upto i ! < Ni·AI Bronze 8148 Ni-AI Bronze B148 NPS 2 & NI-AI i RPTFE Inconel X· C All ~ i-I UNS C95800 above UNS C95800 Bronze B148 ' 750 opper oy CC i NP52 In internally UNS C95800 i , CD

HI Brackish Water (With no coated CS piping above NPS 2 ; I ~ I H25}.Fire Water Bronze 861(UNS Bronze 861(UN5 : a

C92200) upto NPS 1 Y. C92200) upto ~ ) 4 & NI-AI Bronze B148 Ni-AI Bronze B148 NPS 1 Y. & Ni·AI i RPTFE Inconel X· C All

I I UNS C95800 above UNS C95800 Bronze B148 750 opper oy NPS 1 Y. in RTRP UNS C95S00 i piping above NPS 1 %

i Chemical Injection, Instrument : In I X- A19388MIA194 ! 5 Air,Rich Glycol,any other non· 31655 31655 31655, RPTFE .c~~~ 8M , sour service with 55 piping

Hydrocarbon Oil,Gas & Condensate with Chloride ,A193 B7MfA194

6 content less than or equ~I,to 50 CS·A105 or A216- 3165S 316S5(Note.1)' RPTFE Inconel X· 2HM wit~ Electro-pp:n (sour service) for minimum WCB 750 Zinc Plating as per ;;0 design temperature upto minus ASTM 8633 IT!

29°C 'I ~ I ~

c 0 0 . z p

Sr.No. Fluid Handled Body,Bonnet Stem,Trunnion Ball ! Seat ~1,;;!~ote'l Spring ! Body Studs,Nuts " 0 i 0

Hydrocarbon Oil,Gas & , I

== Condensate with Chloride A320 L7M with "tJ 7

content less than or equal to 50 L TCS·A350 LF2/A352 316SS 316SS(Note-1) RPTFE Inconel X- Electro-Zinc I

ppm (sour service) for minimum LCB 750 Plating as per 0 ! W

design temperature below minus ASTM B633 w 29°C and upto minus 46°C "tJ » i :;;0 Hydrocarbon Oil, Gas & I -I Condensate with Chloride ! A193 B7M/A194

6 Mo Austenitic ~

8 content greater than 50 ppm CS·A105 or A216- 6 Mo Austenitic SS

SS(UNS! RPTFE Inconel X- 2HM with Electro·

(sour service) for minimum WCB (UNS NOB926) 750 Zinz Plating as per design temperature upto minus NOB926) r ASTM 8633

29°C

Hydrocarbon Oil, Gas & ! "tJ

I

i II) Condensate with Chloride A320 L7M with CC

content greatertban 50 ppm L TCS-A350 LF2/A352 6 Mo Austenitic SS 6 Mo Austeni\ic Inconel X· Electro·Zinc ft)

9 (sour service) for minimum LCB (UNS NOB926) SS (UNS : RPTFE 750 Plating as per W

NOB926) . en design temperature below minus ASTM B633 0

29°C and upto minus 46°C i ~

W Hydrocarbon Oil,Gas, I .....

I 10 Condensate, and Rich Glycol 316SS 316SS 316SS(Note-1) RPTFE Inconel X· A193 BBM/A194

PipiMlSour Serviclti 750 BM

Effluent Water, Oily Super Duplex Super Duplex Super Duple/< Stainless Steel Inconel X. A193 BBM/A194

11 Water,Produced Water,Oft·Spec Stainless Steel with Stainless Steel with with PREN

RPTFE 750 BM Oil (sour service) PREN exceeding 40 PREN exceeding 40 exceeding 40

Note-1-Solid 316 SS Ball for Valve sizes upto 12" and CS Bali+ENP coating for Valve sizes 14" and above Note 2-For classes 900 and above, metal to metal seat shall be considered. Materials used for valves in sour service shall conform to the requirements of NACE MR0175 i ISO 15156

:::0 m ~ ~

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ACKNOWLEDGEMENT

This KOC Standard has been approved by the Standards Technical Committee (STC) consisting of the following:

Mr. AlRedha AI-Haddad Mr. Mohammad Emam Mr. S. Kumar Mr. A. Unnikrishnan Mr. Khalaf Hamada Mr. N. Ramanathan Mr. Abdul R. AI-Shammari Mr. Ali Hassan AI-Failakawi Mr. Daniel Pino Mr. Haithem Aboghait Mr. Gopal Murti Mr. Abdul Aziz Akbar Mr. Richard Arthur

Standards Team Insp. & Corr. Team (S&E) Standards Team Standards Team Design Team Export Facilities Team Insp. & Corr. Team (N&WK) HS & E Systems Team Utilities Team General Projects Team Opns Tech Svcs Team (WK) Project Mgmt. Team (NK) Info Systems Planning Team

Chairman Dy/Chairman Secretaryl Member Member Member Member Member Member Member Member Member Member Member

The draft of this KOC Standard had been-circulated to-the KOC User Teams for review and the responses were received from the following:

TECHNICAL SVCS DIRECTORATE Team Leader HSE (TS)

SOUTH & EAST KUWAIT DIRECTORATE Team Leader HSE (S&EK)

EXPORT & MARINE OPNS. GROUP Team Leader Export Maintenance Team Leader HSE

MAJOR PROJECTS GROUP Team Leader Project Support

AHMADI SERVICES GROUP Team Leader Utilities Team Leader Proj. Design

OPERATIONS GROUP (SK) Team Leader Opns. Tech. Svcs

SUPPORT SVCS GROUP (S&EK) Team Leader General Projects

NORTH KUWArr DIRECTORATE Team Leader HSE (NK)

WEST KUWAIT DIRECTORATE Team Leader HSE (WK)

ENGINEERING GROUP Team Leader Design Team Leader Construction

HSEGROUP Team Leader HS& E Systems Team Leader H& E Team Leader Safety

GAS MANAGEMENT GROUP Team Leader Consumers Networks Team Leader Gas Operations

SECURITY & FIRE GROUP Team Leader Fire

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~------------------~------------~----------------~r DOC. NO. KOC-MP-033 PART 1 Page 37 of 37 REV. 1

This KOC Standard for Valves: Part 1- Ball Valves (KOC-MP-033) has been prepared by the Task Force (TF-MPI14) comprising ofthe following members:

Mr. Mohsin Mirza Mr. H. Reddy Mr. K. Subramanian Mr. Ashish Kumar

Standards Team 1& C Team (N&W) I & C Team (S&E) Design Team

TF leader & Author Member Member Member

Ex: 61371 Ex: 61479 Ex: 61574 Ex: 61768

D