TECHNICAL SUPPLY CONDITIONS FOR PIPING VALVEStenders.hpcl.co.in/tenders/tender_prog/TenderFiles/2513/Tender... · All piping components shall conform to the requirements of ASME B31

VISAKH MARKETING INSTALLATION RESITEMENT

PROJECT - WHITE OIL TERMINAL

Doc. No:254624-400-SP-PIP-013 Rev: B Page 1 of 32

P:\Andheri\IndiaProject\254624 HPCL- White Oil Terminal\Procurement\Piping\4 inch & above valves\Working\Piping\19.08.09\MR for Valves(4in & above)\Latest\Annexure B-5a.doc

TECHNICAL SUPPLY CONDITIONS

FOR

PIPING VALVES

Mott MacDonald Consultants (India) Pvt. Ltd.

Kothari House, CTS No. 185

Off Andheri - Kurla Road

Andheri (East)

Mumbai 400 059

Hindustan Petroleum Corporation Ltd

Visakha Dispatch Station

VR-ATP Area, Naval Base Post

Visakhapatnam - 530 014

Andhra Pradesh





ALL ‘B’ REVISIONS ARE HIGHLIGHTED IN BOLD





List of Contents Page

1 Scope 6

2 Order of Precedence 6

3 Codes and Standards 6

4 Exceptions to Specified Requirements 6

5 Units of Measurement 7

6 General Requirements 7

7 Construction Features 7

8 Gear Operator Requirements 9

9 Test & Inspection 10

10 Markings 11

11 Painting & Coatings 11

12 Substitutions and Variations 12

13 Packing 12

14 Certification & Traceability 12

15 Maintenance Spares 13

16 Dispatch 13

17 Guarantee 13

Annexure I: Gate & Globe Valves 14

Annexure II: Check Valves 16

Annexure III: Ball Valves 18

Annexure IV: Butterfly Valves 20

Annexure V: DELETED 22

Annexure VI: Non Destructive Examination (NDE) for Valve Castings 23

Annexure VII: Codes, Standards and Specifications 26

Annexure VIII: 29

Table 1 - Non-Destructive Testing Requirements 30





Table 2 - NDE Method And Acceptance Criteria 31

Annexure IX: Pressure Testing Requirements 32





1 Scope

This specification covers the technical, manufacture and inspection requirements of commonly used

valves for process & utility services. This document specifies the minimum requirements governing

the supply of all piping components, whether supplied as bulk materials or as part of an equipment

package unit. It forms an integral part of any Enquiry, Material Requisition or Purchase Order

package for piping components and shall be read in conjunction with the documentation referenced

therein.

1.1 Where ‘Consultant’ is referred to this shall mean Mott MacDonald Consultants India Pvt Ltd.

1.2 Where ‘Vendor’ is referred to this shall mean the Vendor of the Valves & Packaged equipments

against the enquiry or purchase order.

1.3 Where ‘Owner’ is referred to this shall mean Hindustan Petroleum Corporation Limited.

2 Order of Precedence

Any conflict between any requirements specified in this document and the requirements of any

other relevant referenced document shall be resolved in the following order of precedence:

• The Purchase Order Specification, Enquiry or Material Requisition.

• This Document;

• Other reference Project Specifications referred to in this Document.

• Referenced Codes and Standards.

3 Codes and Standards

All piping components shall conform to the requirements of ASME B31.3 (2006) and the relevant

referenced Codes, Standards and Specifications, listed in Annexure VII.

Other Codes or Standards may be specifically referenced in a Stock Code Description (Material

Requisition Item Number Description). In these cases, the requirements of the Code or Standard so

referenced take precedence over any conflicting requirements of ASME B31.3 or any relevant Code

or Standard referenced therein.

In case of conflict between Valve Technical Specification sheet and PMS, Valve Technical

specification sheet shall govern.

All codes and standards for manufacture, testing, inspection etc. shall be of latest editions.

4 Exceptions to Specified Requirements

Exceptions to the specified requirements of the enquiry package will only be considered by the

OWNER / Consultant on a case by case basis for valves or materials procured within the State of

India, provided that the valves or the materials comply with applicable Indian codes and standards.





5 Units of Measurement

5.1 Metric (SI) units of measurement shall be used throughout.

5.2 Nominal pipe sizes (NPS), bolt lengths and diameters shall be expressed in inches.

5.3 Nominal pressure ratings for valves are expressed in pounds (e.g., 150 LB, 3000 LB, etc.). Where

metric (SI) nominal pressure rating designations are used (i.e., PN), the relationship shall be as

follows:

PN20 = 150 LB

6 General Requirements

6.1 All material shall be new and unused and shall be free of detrimental foreign matter.

6.2 Piping valves within packaged equipment shall comply with the applicable Piping Material Classes

in the Project Specification. VENDOR’s supplying packaged equipment shall identify in their

quotation, any piping valves within the packaged equipment which does not comply with project

specification and shall include enough details regarding the material composition of those valves,

and the services for which they are intended, to enable OWNER / Consultants to judge their

suitability for the intended service.

6.3 Valve of sizes 1/4", 3/8", 1-1/4", 2-1/2", 3-1/2", 5" and 22" shall not be used.

7 Construction Features

7.1 DELETED

7.2 Valves shall be as per the appropriate valve specification sheets.

7.3 Valves shall be capable of satisfactory operation with the valve stem in any position i.e. vertical,

horizontal or inclined.

7.4 Pressure temperature rating for flanged and butt welding end valves shall be as per ASME B16.34

except for ball, butterfly valves. Valve thickness of valve body at different locations should not be

less than as calculated as per ASME B16.34. For ball and butterfly valves, manufacturer’s

recommendations shall be obtained before use for intended service.

7.5 End requirements shall be as follows :-

a) Butt welding ends shall conform to ASME B16.25.

b) Socket welding ends shall conform to ASME B16.11.

c) Threaded ends shall conform to ASME B1.20.1.

d) Flanged ends shall conform to ASME B16.5 for sizes ½” NPS to 24” NPS.

7.6 No cast, ductile or malleable Iron, aluminum, plastic or copper bearing alloy shall be used in

Hydrocarbon service.

7.7 Valve body/bonnet shall be forged / cast as specified. Forgings are acceptable in place of casting but

not vice-versa.

7.8 Stem shall be forged or machined from forged/rolled bar. No casting is permitted. However, integral

stem of cast stainless steel ball valve is acceptable.

7.9 Hand wheel wherever used for valve operation shall not be of cast iron. Material for hand wheel

shall be either malleable iron or cast steel.





7.10 Stelliting / hard facing by deposition shall be minimum 1.6 mm thick. Renewable seat rings shall be

seal welded.

7.11 All material shall be new, clean and free from rust, pits and obvious defects.

7.12 Spiral wound bonnet gaskets are to be provided with inner/outer ring except when encapsulated

gaskets type body-bonnet joints are employed. Outer ring may be omitted in the case of non-circular

spiral wound gasket used in Class 150 valve provided the outermost layer of spiral touches the bolts

ascertaining the centring.

7.13 Where ring joint gaskets are used for the body to bonnet joint the hardness of ring of gasket shall be

lower than the valve body and bonnet

7.14 The term ‘Valve Trim’ is defined as “All wetted internal parts of a valve”.

7.15 Valves shall be installed for ease of operation and maintenance. Valves shall not be installed with

their stem below horizontal.

7.16 The manufacturer shall ensure the interchange ability of parts between valves of same size and

specification by specifying proper tolerances during manufacture. To check compliance with this

clause, the Inspection Engineer shall have the authority to select any two valves of the same size

and specification and ask the Vendor to interchange the parts and carry out necessary tests after the

assembly.

7.17 All gate and globe valves shall have back seating arrangement to facilitate replacement of gland

packing while in open position. Back seat bush shall be renewable.

7.18 Hardness requirements for trim material shall be as follows:

a) Wherever body seat and disc seat materials are specified as 13% Cr, hardness of disc seat shall

be 250 BHN (Min) and Hardness of body seat shall be 50 BHN more than disc seat.

b) For carbon steel Valves, wherever 13% Cr is specified for disc and disc seat, 13% Cr by weld

deposit on ASTM A216 Gr. WCB casting is acceptable for Valve Sizes 6” and above only.

7.19 Gate and globe valves of rating Class 300 and above shall have gland stuffing boxes of sufficient

depth to accommodate lantern rings in addition to gland packing.

7.20 DELETED

7.21 DELETED

7.22 All flanged valves shall have flanges integral with the valve body. However, forged valves can have

weld on flanges with full penetration joint and with 100% radiography of the attached welds

7.23 Flange facing finish shall be as per MSS SP.6. Flange face finish shall be normally specified in the

valve specification sheet. The interpretation of range of finish shall be as described as follows:

a) 63 to 125 RA for smooth finish

b) 125 to 250 RA for serrated finish.

7.24 All valves with non-metallic seats and seals in hydrocarbon service shall be fire-safe type. Fire safe

test shall be as per API-607 (LATEST), API-6FA or BS EN 12266 Part II (LATEST).

7.25 Fire safe test witnessed and certified by an approved third party inspection agency (e.g.

LLOYDS/BV/DNV/EIL/CEIL) shall be furnished to the OWNER / Consultant for Approval.

7.26 Soft-seated ball, and butterfly valves shall be supplied with antistatic devices.

7.27 Wherever Lock Open (LO) / Lock Close (LC) specified in the valve MTO, the valve shall be

provided with locking arrangement such as pad lock and chain.

7.28 The padlocks supplied for ‘LO’ &’LC’ valves shall be heavy duty stainless steel weatherproof

construction suitable for outside use to fit the valve. The vendor shall supply 3 (three) keys for each

padlock on two heavy duty split rings with two stainless steel tags hard stamped or permanently

etched with the valve part number and tag.





7.29 Hand wheel diameter shall not exceed 750mm and lever length shall not exceed 500mm on either

side. Effort to operate shall not exceed 35 kg at hand wheel periphery. However failing to meet the

above requirements, vendor shall offer gear operated valve.

7.30 Socket weld end valves with non-metallic seats or seals shall be provided with 80mm long nipples

having materials and thickness equivalent to those specified in the relevant piping specifications..

These nipples shall be welded to both ends of the valve by the Vendor, before fitting packing, seats

and seals.

7.31 LIMIT SWITCH REQUIREMENT:

Where ever data sheets calls for requirement of limit switch following shall apply.

o Each valve shall have two switches (open & close) & these shall be Inductive proximity

type, 2 wire, 24 VDC and shall be providing a switching output. It shall be enclosed

within housing so as to comply with the Hazardous area classification zone-ІІ.

o Limit switch shall be supplied with pre-fab cable terminated in a JB mounted on the

valve.

o Cable entry shall be 1/2" NPT. EExd certified adaptors are acceptable where ½” NPT

cable entries are not provided.

o Flameproof Nickel plated brass; double compression cable glands shall be provided.

Cable gland shall be covered with shroud.

o Suitable anti-vibration terminal blocks shall be provided for cable termination.

Terminals shall be clip-on type (screw less).

o The valve shall be equipped with a mechanical direct-coupled travel or position

indicator for local status indication. The position indicator shall be provided with a

transparent cover for protection.

o Limit Switches shall be with mounting bracket & shall be mounted on valve while

supplying.

o JB/Enclosure housing shall be minimum IP 65 with die cast aluminium as enclosure

material of construction.

8 Gear Operator Requirements

8.1 Gear operators shall be provided for valves in accordance with the following Table, with the

exception that:- if any valve specified with handwheel or lever requires a torque of 271 NM or more

to open or close against a maximum differential pressure, then that valve shall be supplied with a

gear operator even if not specified in the purchase description.

8.2 Gear operator when required and supplied shall be totally enclosed Helical worm or Bevel gears in

weather resistant metallic grease box manually operable by hand wheel. It shall have a position

indicator for open/close and intermediate positions.

8.3 For gear operated valves, gear ratio shall be such that operating torque shall be less than 25 kg-m,

with the differential pressure across the valve equal to the cold non shock pressure rating.





8.4 Unless noted otherwise, Gear operator shall be provided for valves on the following basis.

------------------------------------------------------------------------------ Valve Type ANSI Class Valve Size

------------------------------------------------------------------------------ Gate, Globe 150 & 300 14” & Larger

DELETED

Ball 150 & 300 6” & Larger

DELETED

Butterfly 150 6” & Larger

8.5 Lever operated valves shall have Ball and Butterfly stem heads with a key way for attaching the

wrench. Circular stem heads with one or two flats are acceptable but in all cases the design must be

such that the wrench cannot be installed in a manner that allows the ball to be rotated more than

90°. Square stem heads are not acceptable. The lever/wrench shall be at 90° to pipe center line when

the valve is closed. Stops shall be fitted at the fully open and fully closed position to prevent the ball

from moving through more than 90°.

9 Test & Inspection

9.1 DELETED

9.2 Where stated on the valve data sheet, fire type-testing shall be in accordance with BS EN 12266

Part 2 or API 607 or API 6FA, as applicable.

9.3 In addition to the normal seat test as specified all non return valves shall be tested for leakage at

25% of the specified seat test pressure. Also a test should be carried out to ensure that all non return

valves start opening at 0.2kg/cm2 differential pressure across the valve.

9.4 Every valve, its components and auxiliaries must be subjected to all the mandatory tests and checks

called for in the respective codes, data sheets etc. by the manufacturer.

9.5 The sequence of pressure testing of soft seated valves shall be as follows:

First the hydro test for body shall be performed, after this the hydro test for seat shall be done and

then the low-pressure air test shall be performed. In case the valve does not pass the low-pressure air

test and leakage is observed through the seat, vendor shall replace the seats and low-pressure air test is

to be repeated.

9.6 DELETED

9.7 Following Inspection procedure shall be applicable where 10% radiography of casting is specified :

a) 10% Radiography is specified to indicate that 10% of the quantity ordered per size per heat

shall be radiographically tested, fractions shall be rounded off to 1 to decide the number of

casting to be radiographically examined.

b) In case of rejection, double the quantity of the casting to be radiographed as determined by

9.7.(a) above shall be offered for radiography. In the event of further rejection of single casting,

the whole lot shall be radiographed.

c) The extent of radiography shall be restricted only to the critical areas as defined in ANSI

B16.34. Acceptance of radiography is as defined in ASTM E446.

9.8 All valves shall be hydrotested & pneumatically tested for body & seat as per respective valve

datasheet.

9.9 DELETED





9.10 DELETED

9.11 Valve body thickness, wherever not specified in the standard, shall be as per ASME B 16.34.

9.12 DELETED

9.13 Hydrostatic testing shall be completed using potable water containing 1% by volume of

biodegradable wetting agent. Maximum chloride and fluoride content shall be 20ppm and the pH

value shall be between 6.0 and 8.0.

9.14 Castings shall not be impregnated with any material to prevent leakage.

9.15 Upon completion of satisfactory testing all components to be thoroughly drained and dried prior to

preparation for packing.

9.16 Quality Plans shall be submitted for review with the bid. All valves and speciality components will

be subject to inspection in accordance with the OWNER / Consultant approved Vendor Quality

Plan.

9.17 Vendors shall, as a minimum be ISO 9001:2000 or equal accredited, with manufacturers preferably

having ISO 9001:2000 or equal accreditation as well.

9.18 The Vendor shall provide full facilities/access for inspection by the OWNER / CONSULTANT’s

representative during the course of manufacture. The Vendor shall also arrange for the same

facilities/access to be made available at Sub-Vendors works, where deemed necessary by the

OWNER / CONSULTANT.

10 Markings

10.1 Valve marking, symbols, abbreviations etc. shall be in accordance with MSS-SP-25 or the standard

referred in the specification sheet as applicable. Vendor’s name, valve rating, material designation,

nominal size, direction of flow (if any) etc. shall be integral on the body.

10.2 Each valve shall have a corrosion resistant tag of stainless steel/aluminum giving size, valve tag no.

/code no. and pressure class rating securely attached to the valve body.

10.3 Paint or ink for marking shall not contain any harmful metal or metal salt such as zinc, lead or

copper which cause corrosive attack on heating.

11 Painting & Coatings

11.1 Unless otherwise specified, painting & coatings shall be done as per Clause 6.1 of API-600.

11.2 All carbon steel valves components and corrodable external parts shall be supplied primer coated as

follows :

a) Preparation: Shot blast to Swedish Standard SA2½

b) Primer coat: Inorganic Zinc Primer 75 microns DFT minimum.

11.3 For 1¼ Cr- ½ Mo material the Vendor shall propose a suitable primer system to accommodate

design temperature of 550 deg C.

11.4 Painting shall be carried out after successful completion of all testing and inspection.





12 Substitutions and Variations

12.1 Where a Vendor wishes to supply a suitable alternative to that specified in the data sheet, they shall

submit a specification of alternatives to the OWNER / Consultants for approval at the bid stage.

12.2 In the event of an order, the Vendor shall make no substitutions or variations to the requirements of

that order without written approval from the OWNER / Consultants.

12.3 Where the Vendor wishes to make a substitution or variation to an item on the order, the Vendor

shall complete the OWNER / Consultant’s “Concession Request Form” and return this form for

approval. If variation will affect the data sheet, this should also be attached showing the change.

12.4 The OWNER / Consultants will review each completed Concession Request Form issued by the

Vendor for the Order, for acceptance or rejection.

12.5 Approved Forms shall be sent to the Vendor for inclusion in the Dossier and Rejected Forms shall

be sent for action.

13 Packing

13.1 All valves shall be packed after inspection taking particular care for protection of the valve yokes

and flanges. The flanges shall be closed with plate covers; ends of threaded and socket and welding

valves shall be closed using plastic caps.

13.2 All valves having grease seal stem or seat shall be shipped free of grease and provided with suitable

protection for grease fittings and stem to prevent shipping damage.

14 Certification & Traceability

14.1 All valves and speciality components shall be certified and copies of all documentation shall be

supplied for each valve and speciality component. Blanket certification is not acceptable. If more

than one component is on a certificate each component must be identified by the Contractor’s tag

number and purchase order number and Manufacturer's serial number, and certificates for each

valve must be listed for that valve.

14.2 Certificates shall be provided and the number of copies called for will be stated in the Contractor’s

Documentation Specification covering each item supplied. All certificates shall be fully traceable to

the item covered and shall be marked with the Contractor’s order number, item number and tag/part

number. They shall be clearly legible, in the English language.

14.3 Material Certificates for basic material i.e. plate, forgings, or castings used in the manufacture of

flanges and valve bodies, bonnets and pressure retaining parts shall be furnished as test certificates

of the EN 10204 3.1B type. Vendor shall confirm which parts are considered pressure retaining and

shall include a list in the bid for Contractor review.

14.4 The certificates shall be issued, stamped and signed by the material Manufacturer's inspector, who

shall be independent of the Manufacturer's Production Department. This certificate shall also be

stamped and verified by the valve Manufacturer's QA/QC Department.

14.5 Where basic material is further processed by the Vendor to form the valve body or valve

components and such process may change the mechanical properties, etc., the Vendor shall also

furnish EN 10204 -3.1B type certificates for the Manufacture of the furnished item.

14.6 For valve internals and non-pressure containing parts works reports of the BS EN 10204 2.2 type

shall be acceptable.

14.7 The Vendor shall supply certificates of conformity for non-metallic components of valves.





15 Maintenance Spares

In case of diaphragm valves, and piston valves, bidder should furnish a complete list of

maintenance spares required for two years trouble free operation along with recommended

quantities and quote the price for the same.

16 Dispatch

16.1 Each end of the valve shall be protected with the following materials:

Flange face : Wood or plastic cover

Bevelled end : Wood or plastic cover

SW or Scrd.End : Plastic cap

16.2 End protector of wood/plastic to be used on the flange faces shall be attached by at least three bolts

and shall not be smaller than the outside diameter of the flange. However the plastic cap for SW &

Scrd. End valves shall be press fit type.

16.3 End protectors to be used on bevelled end shall be securely and tightly attached.

16.4 For special service valves additional requirement of despatch shall be prescribed in datasheet.

17 Guarantee

17.1 All valves and their components shall be guaranteed for trouble-free operation for a period of 12

months from the date of commissioning against the medium as listed in individual technical

specification and the service condition specified in the Pipe Specification Index enclosed.

17.2 Vendor shall guarantee all equipment as being suitable for the design conditions and service fluids

stated in the Piping Specification Index for the pipe class specified in valve data sheets.

17.3 Confirmation of suitability shall be stated in the Vendors bid e.g. seats, seals etc.





Annexure I: Gate & Globe Valves

1. General

1.1 Steel Gate Valves shall conform to one of the following Standards.

API 600 for sizes 2" through 24" and in general for larger sizes.

API 602 for sizes 1/2" through 1-1/2"

1.2 Steel Globe Valves shall conform to the following standards

BS EN ISO 15761 for sizes 1/2" through 1-1/2"

BS 1873 for sizes 2" and larger.

1.3 The welding of flanges on to valves to meet the requirements for a flanged end valve is not

acceptable without prior approval.

1.4 A one-piece wedge shall be solid, a welded fabrication is not acceptable.

1.5 Lantern rings and leak-off plugs shall not be fitted unless specified.

1.6 Unless otherwise mentioned in the P&ID, by-pass shall be as follows :

1.6.1 DELETED

1.6.2 By-pass valve shall be a globe valve. The sizes of globe valve shall be as under:

On main valve upto 4” = ½” or more

On main valve 6” to 8” = ¾” or more

On main valve 10” & above = 1” or more

1.6.3 Vendor shall supply the by-pass valve duly tested and fitted to the main valve. Valves with by-pass,

shall have the direction of flow marked on the main valve. By-pass attachment to the main valve

body shall not be screwed. All the fillet welds for by-pass installation shall be 100% examined by

DP/MP test.

1.6.4 The by-pass piping arrangement shall be such that clearance between main valve body and by-pass

assembly shall be the minimum possible for the layout reasons.

1.7 Valve body/bonnet shall be forged/cast as specified. Forging are acceptable in place of casting but

not vice-versa.

1.8 Material of the construction of the yoke shall be minimum equivalent to body/bonnet material.

1.9 Stem shall be forged or machined from forged/rolled bar. No casting is permitted.

1.10 Stelliting / Hardfacing by depositions shall be minimum 1.6 mm. Renewable seat rings shall be seal

welded.

1.11 If any overlay weld-deposit is used for the body seat ring, seating surface, the seat ring base

material shall be at least equal to the corrosion resistance of material of the shell.

1.12 ALL gate/globe valves shall have solid wedge for sizes 11/2” and below and flexible wedge for

sizes 2” and above.

1.13 All valves that require a torque of 271 Nm or more to open or close a valve against the maximum

differential pressure for which the valve is designed, shall be supplied with a gear operator, even if

not specified in the purchase description.

1.14 Gear operators shall be totally enclosed weatherproof type packed with a suitable lubricant, and

fitted with a grease nipple.





1.15 Where ring joint gaskets are used for the body to bonnet joint it shall be an Oval Ring and of

hardness lower than the body and bonnet.

1.16 Valves supplied by Indian Vendors may use non-metallic gaskets or part of gaskets, or gland

packing to Indian Standards.

1.17 The carbon content of valve bodies with welding ends, and bodies and bonnets on valves with

welded bonnets shall be 0.25% maximum.

1.18 Gate valves 2" and larger shall be supplied with a flexible wedge.

1.19 All globe valves shall be of guided disc design and suitable for installing in all positions like stem

horizontal, vertical, and inclined etc.

1.20 All fillet welds such as for jacket welds etc. on valve body shall be 100% DP/MP tested.

1.21 All valve body castings shall be of radiographic quality to ASME B16.34 ANNEX. B and shall be

govern by the non-destructive testing requirements as per ANNEX –II.

1.22 Stem protection is required for all CS gate and globe valves where 11-13% Cr trims are specified.

The stem shall be totally enclosed in a sleeve, which shall be packed with grease.

2. Identification Marking Requirements

2.1 For bodies or bonnets the heat or melt number shall be marked and shall be traceable to the relevant

material certificate.

2.2 A metal tag shall be attached as specified under Clause 10 (Markings) of this document. Tags shall

be stainless steel or brass, a minimum of 1 mm thick, and are to be securely wired around the gland

studs with stainless steel wire of a minimum diameter of 1 mm, additionally the Stock Code number

shall be hard stamped on the bonnet flange rim in 3 mm high characters minimum.

3. Testing

3.1 The test fluid for hydrostatic testing shall be water containing a suitable corrosion inhibitor. The

water shall have a maximum chloride content of 20 ppm. The valve shall be thoroughly dried

before despatch.

3.2 DELETED

4. Certification

4.1 Material Certificates in accordance with DIN 50049 3.1.b are required for Bodies and Bonnets and

as a minimum shall include

a) Chemical Analysis by Product

b) Mechanical Properties

c) Heat Treatment Statement

d) Non Destructive Test results

e) Hydrostatic and/or Pneumatic Test results

f) Heat or Melt Number

4.2 All certificates shall state the Manufacturers name and location, all forging and casting certificates

shall be from original forge or foundry. Certificates shall include the OWNER / Consultants

purchase order number and purchase order item number.





Annexure II: Check Valves

1. General

1.1 Steel Check Valves shall conform to one of the following Standards;-

BS EN ISO 15761 for sizes 1/2" through 1-1/2".

BS 1868 for Swing Check Valves 2" and larger.

API 594 for Wafer Check Valves.

1.2 Unless specified otherwise in the data sheet all the check valves 3” & above (except in 900#, 1500#

& 2500# rating) shall have a drain boss. A tapped drain hole with plug shall be provided as per

ASME B 16.34. Threads shall be as per ASME 1.20.1 (Taper) NPT.

1.3 Wherever check valve disc assembly is supported from the cover of check valves the following

shall be ascertained.

a) Positive location / positioning of cover must be provided to ensure correct alignment of valve

disc.

b) Hinge pin design must permit accurate alignment of the disc and valve seat.

1.4 For heavy check valves (50 kg & above), provisions shall be available for lifting by way of lugs,

eyebolts and other such standard devices.

1.5 Piston lift check valves shall be installed only in horizontal lines. Swing type check valves shall not

be installed in vertically downward flowing lines.

1.6 The welding of flanges on to Swing Check valves to meet the requirements for a flanged end valve

is not acceptable without prior approval.

1.7 Where ring joint gaskets are used for the body to bonnet joint on Swing Check Valves it shall be an

Oval Ring and of a hardness lower than the body and bonnet.

1.8 Valves supplied by Indian Vendors may use non-metallic gaskets or part of gaskets to Indian

Standards.

1.9 The carbon content of Swing Check Valve bodies with welding ends shall be 0.25% max.

1.10 All Swing Check Valves shall have an integral cast boss at position G in accordance with ASME

B16.34.



governed by the non-destructive testing requirements as per ANNEX –II.


2.1 For bodies or bonnets the heat or melt number shall be marked on and shall be traceable to the

relevant material certificate.


be stainless steel or brass, a minimum of 1 mm thick, and are to be securely wired around the Valve

Body with stainless steel wire of a minimum diameter of 1 mm, additionally the Stock Code number

shall be hard stamped on the cover flange rim in 3 mm high characters minimum.





3. Testing

3.1 The test fluid for hydrostatic testing shall be water containing a suitable corrosion inhibitor. The

water shall have a maximum chloride content of 20 ppm. The valve shall be thoroughly dried

before despatch.

3.2 For jacketed valves in addition to the testing of valve the jacket shall be tested as per the

valve specifications and shall be thoroughly dried.

4. Certification

4.1 Material Certificates in accordance with DIN 50049 3.1.b are required for Bodies and Covers and as

a minimum shall include







g) Fire Safe Test Certificates


shall be from original forge or foundry. Certificates shall include the OWNER / Consultants

purchase order number and purchase order item number.





Annexure III: Ball Valves

1. General

Steel Ball Valves shall conform to the following Standard;-

1.1 The welding of flanges on to valves to meet the requirements for a flanged end valve is not

acceptable without prior approval.

1.2 All Ball valves shall be "Fire Safe" in accordance with either API 607 or BS EN 12266, Part-2 and

have anti-static devices in accordance with BS EN ISO 17292. Fire safe certificates shall be

submitted, prior to manufacture, to cover the valves on the Purchase Order.

1.3 The Ball shall be of a one-piece solid construction with a continuous through bore, welded-in liners

are not acceptable.

1.4 The ball of the ball valve shall not protrude outside the end flange of the valve.

1.5 All ball valves shall be Bi-directional.

1.6 Ball shall be solid type unless otherwise specified.

1.7 Body seat shall be renewable type.

1.8 All ball valves shall be forged type for 1 ½ “ & below.

1.9 All Ball valves shall be supplied with position indicator.

1.10 Ball valves shall be floating ball type/trunnion mounted as per following:

150# 8” & smaller Floating ball

10” & larger Trunnion mounted

1.11 All trunnion-mounted ball valves shall be provided with spring loaded seat rings.

1.12 Trunnion-mounted ball valves shall be supplied with provision for double block and bleed.

1.13 Unless otherwise specified in the data sheets, bore of all reduced bore ball valves shall be limited to

one size lower than the nominal bore. Full-bore valves shall be provided for piggable lines.

1.14 Ball valves even with wrench or lever operators shall have “Open” Position indicators with limit

stops.

1.15 Stem retention shall not depend on the packing gland, Removable Stem retaining parts inside the

Valve body are not acceptable, Stem shall be of an anti-blow out design.

1.16 All Ball valves are required to provide automatic body cavity pressure relief to prevent over

pressurisation when valve is closed. Vendors to advise when Quoting which side will vent and

whether a specific vent direction can be offered.

1.17 All Valves specified as socket weld shall be supplied fitted with factory welded in pipe nipples to

give an overall length of 300 mm, nipples to be a minimum thickness of schedule 80 for carbon

steel and of a material similar to the valve body.

1.18 Where ring joint gaskets are used for the body to bonnet joint it shall be an Oval Ring and of

hardness lower than the body and bonnet.

1.19 Valves supplied by Indian Vendors may use non metallic gaskets or part of gaskets, or gland

packing to Indian Standards.

1.20 High Pressure closure test (seat hydrostatic test) shall be conducted on all ball valves as per the

relevant test standards.








1.23 Ball valve cavities shall be vented to relieve excess pressure. Venting may be achieved through self-

relieving seat design or by drilling a hole in the bore. The direction of flow shall be permanently

marked on the valve body. The cavity venting side of the valve shall also be permanently marked on

the valve

1.24 Material selection for soft seats/seals for Ball valves shall be suitable for maximum differential

pressure, corresponding to pressure/temperature rating and service fluid handled on a continuous

basis. The seat/seal material in valve data sheets for Ball valves is indicative only .Vendor can

propose an alternative seat provided he furnishes the pressure/temperature rating of the proposed

seat material which shall cover the class temperature pressure rating of the valve and is superior to

the seat/seal material specified in the valve datasheets.


2.1 For bodies or bonnets the heat or melt number shall be marked and shall be traceable to the relevant

material certificate.


be stainless steel or brass, a minimum of 1 mm thick, and are to be securely wired around the gland

studs with stainless steel wire of a minimum diameter of 1 mm, additionally the Stock Code number

shall be hard stamped on the bonnet flange rim in 3 mm high characters minimum.

3. Testing

3.1 The test fluid for hydrostatic testing shall be water containing a suitable corrosion inhibitor.

3.2 The water shall have a maximum chloride content of 20 ppm. The valve shall be thoroughly dried

before despatch.

4. Certification










shall be from original forge or foundry. Certificates shall include the Contractors purchase order

number and purchase order item number.





Annexure IV: Butterfly Valves

1. General

1.1 Steel Butterfly Valves (excluding lined valves) shall conform to API 609.

1.2 Valves are to be suitable for installation with the operating shaft in the vertical plane.

1.3 Valves shall be hydrotested in accordance with API 598.

1.4 Valve stem packing shall be adjustable by means of an external gland.

1.5 Valves shall have an anti-blow out shaft design.

1.6 Valves supplied by Indian Vendors may use gaskets or part of gaskets, or gland packing to Indian

Standards.

1.7 Valves that are torque seated or require a torque of 271 Nm or more to open or close against the

maximum working differential pressure shall be fitted with a gear operator, even if not specified in

the purchase description.

1.8 Gear operator shall be totally enclosed weatherproof type packed with a suitable lubricant, and

fitted with a grease nipple.




2.1 For bodies and bonnets the heat or melt number shall be marked on and shall be traceable to the

relevant material certificate.

2.2 The valve serial number(s) shall also be noted on the relevant certificate.


be stainless steel or brass, a minimum of 1 mm thick, and are to be securely wired around the Valve

Body with stainless steel wire of minimum diameter of 1 mm, additionally the Stock Code number

shall be hard stamped on the cover flange rim in 3 mm high characters minimum.

3. Testing

3.1 The test fluid for hydrostatic testing shall be water containing a suitable corrosion inhibitor.

3.2 The water shall have a maximum chloride content of 20 ppm. The valve shall be thoroughly dried

before despatch.





4. Certification









g) Valve Serial Number


shall be from original forge or foundry. Certificates shall include the Contractors purchase order

number and purchase order item number.





Annexure V: DELETED





Annexure VI: Non Destructive Examination (NDE) for Valve Castings

1. General

1.1 All castings shall be manufactured in accordance with the requirements given in the Purchase

Order/Contract and shall be of radiographic quality.

1.2 Vendor shall demonstrate it has the experience, quality control and personnel to assure the

production of consistently sound castings.

1.3 Vendor may submit an alternative inspection programme for review and approval at the bid stage.

The submittal should address all of the issues referred to in this Specification.

2. Casting Inspection Requirements

2.1 Valve Bodies and Bonnets shall be subjected to the following inspection with a minimum of one

for each size/ stockcode/ batch

a) Quality D on all castings plus other quality designations mentioned in Table 1

b) Each welding end of all butt weld ended valves shall be subjected to Inspection type Quality

A.Testing shall cover a minimum length of 2”, or as per ASME B 16.34 whichever is higher,

from each end

c) For Valves specified to have Extended Bonnets for low temperature service, Valve casting

weld repairs shall also have the weld deposit impact tested in accordance with ASME B31.3

para. 323.3 at a temperature of minus 185 Degrees C (or lower), as part of the welding

procedure qualification

2.2 A castings quality designation, which indicates inspection requirements are defined as follows:

a) Quality A

Visual examination (Clause 3.2) plus magnetic particle examination (Clause 3.3) or dye

penetrant examination (Clause 3.4) of all accessible interior and exterior surfaces, including

machined surfaces, plus radiography of critical areas (Clause 3.5).

b) Quality B

Visual examination (Clause 3.2) plus magnetic particle examination (Clause 3.3) of all

accessible interior and exterior surfaces including machined surfaces. For non-magnetic

materials, dye penetrant examination methods shall be used (Clause 3.4).

c) Quality C

Visual examination (Clause 3.2) plus magnetic particle examination (Clause 3.3) of machined

surfaces. For non-magnetic material, dye penetrant examination methods shall be used

(Clause 3.4).

d) Quality D

Visual examination in accordance with Clause 3.2





Table 1

Type of Inspection Sl.

No. Material

Rating

(LB) Quality B on 10% of

quantity of castings

Quality A on 10% of

quantity of castings

Quality A on 100%

of quantity of castings

i Carbon Steel 150 & 300 18” and above

ii DELETED

3. Inspection Procedures And Acceptance Standards

a) Surface Preparation

Surfaces of all castings shall be suitably cleaned by chipping or blasting.

b) Visual Examination

All castings shall be visually examined and proven free from sand, scale, cracks, tears, voids

and other harmful effects.

Acceptance levels shall be as specified in MSS-SP-55.

c) Magnetic Particle Examination (MPE)

MPE shall be carried out on ferritic castings in accordance with ASTM E709.

Acceptance Criteria : ASME B16.34, Annex C, Section 2.1

d) Dye Penetrant Examination (DPE)

DPE shall be conducted on non-magnetic castings and where MPE is not feasible. The testing

procedure shall be in accordance with ASTM E165.

Acceptance Criteria : ASME B16.34, Annex D, Section 2.1

e) Radiographic Examination

Radiographic examination of critical areas only shall be conducted as specified in ASME

B16.34. Critical areas are defined as an abrupt change in section, weld ends, at risers, gates or

feeders and areas of highest stress. For valve castings critical areas are as defined Section 8.3 of

ASME B16.34.

Acceptance criteria : ASME B16.34, Annex B





f) Ultrasonic Examination

Ultrasonic examination may be carried out by agreement where radiographic inspection is not

feasible

Procedure : ASME VIII, Div. 1, Appendix 7 or ASTM A609

Acceptance Level : ASTM A609

Quality level as follows:

Thickness Acceptance Level

< 50mm 1

50-100mm 2

> 100mm 3

1. Dimensions

All initial castings and randomly selected castings shall be dimensionally checked to ensure

compliance with the minimum wall thickness specified and the overall dimensions.

2. Submittal of NDE Procedures

For quality standard A & B, NDT procedures shall be submitted for review and approval.

4. Repair Procedures

4.1 The repair of any defect found on castings by plugging, peening, use of plaster or cement

compounds, or impregnation by plastic materials or similar compounds is prohibited. Repairs to the

pressure boundary shall be by welding only.

4.2 Major repairs are defined as those that require removal of 20% of the casting wall thickness or 25

mm which ever is less or those that result in a repair area that exceeds 6,500 mm2. For quality

standard A & B, major weld repair procedures shall be submitted for approval.

4.3 All repairs by welding shall be made by procedures/welders in accordance with ASTM A488. The

analysis of the deposited weld metal shall conform to the nominal analysis of the parent casting.

4.4 After major weld repair all castings shall be heat treated or stress relieved as required by the casting

specification, however, the Buyer reserves the right to specify solution heat treatment for repairs to

austenitic stainless steel where considered applicable for process or environmental reasons.

4.5 All weld repairs shall be re-examined by appropriate methods and as defined in Section 3.0.





Annexure VII: Codes, Standards and Specifications

VENDOR shall comply with the latest edition of the following codes, standards and specifications

as available at the date of contract award:

1 American Society of Mechanical Engineers (ASME)

B1.1-2003 Unified Inch Screw Threads (UN and UNR Thread Form).

B1.20.1-1983 Screw Threads - Pipe Treads, General Purpose (Inch).

B16.1-2005 Cast Iron Pipe Flanges & Flanged Fittings.

B16.5-2003 Steel Pipe Flanges and Flanged Fittings.

B16.9-2007 Factory made Wrought Steel Butt-Welding Fittings.

B16.10-2003 Face to Face and End to End Dimensions of Ferrous Valves.

B16.11-2005 Forged Steel Fittings, Socket Welding and Threaded.

B16.14-1991 Pipe Plugs.

B16.20-2007 Ring Joint Gaskets and Grooves for Steel Pipe Flanges.

B16.21-2005 Non-metallic Flat Ring Gaskets for Pipe Flanges.

B16.25-2007 Butt-Welding Ends.

B16.34-2004 Steel Valves - Flanged, Threaded and Welding End.

B16.36-2006 Orifice Flanges.

B16.47-2006 Large Diameter Steel Flanges

B16.48-2005 Steel Line Blanks

B18.2.1-1996 Square and Hex. Bolts and Screws (Inch Series).

B18.2.2-1987 Square and Hex. Nuts (Inch Series).

B31.1-2007 Code for Power Piping.

B31.3-2006 Code for Pressure Piping – Chemical Plant and Petroleum Refinery

Piping.

B36.10-2004 Welded and Seamless Wrought Steel Pipes.

DELETED

B46.1-2002 Surface Textures.

2 Manufacturers Standardisation Society (MSS)

SP-25: 1998 Standard Marking System for Valves, Flanges and Unions.

DELETED

SP-55 :2006 Quality Standard for Steel Castings for Valves, Flanges, Fittings and

Other Piping Components.

SP-95: 2006 Swaged Nipples and Bull Plugs.

SP-97 :2006 Forged Carbon Steel Branch Outlet Fittings - Socket Welding, threaded

and Butt-Welding Ends.





3 American Petroleum Institute (API)

API 594-2004 Wafer Type Check Valves, Steel.

API 598-2004 Valve Inspection and Testing.

API 599-2007 Flanged and Butt-Weld Plug Valves.

API 600-2006 Steel Gate Valves, Flanged and Butt-Weld Ends.

API 602-2005 Compact Steel Gate Valves.

API 607-2005 Fire Test for Soft Seated Quarter Turn Valves.

API 608-2002 Metal Ball Valves - Flanged and Butt-Welding Ends.

API 609-2004 Butterfly Valves, Lug and Wafer Type.

4 British Standards Institute (BS)

5 International Organisation for Standardisation (ISO)

6 Indian Standards and Regulations (IS)

BS 1868 Flanged and Butt-Weld Swing and Lift Type Check Valves.

BS 1873 Globe Valves, Flanged & Threaded Copper Alloy, Gate, Globe & Check

Valves.

ISO 8501-1 Preparation of Steel Substrates Before Application of Paints and

related Products - Visual assessment of surface cleanliness.

BS EN ISO 15761-

2002

Steel gate, globe and check valves for sizes DN 100 and smaller, for

the petroleum and natural gas industries

BS EN 12266

Part-1-2002

Industrial valves —Testing of valves

BS EN ISO 17292-

2004

Metal ball valves for petroleum, petrochemical and allied industries

BS EN ISO 17292-

2004

Steel Ball Valves for the Petroleum Petrochemical and Allied

Industries.

BS EN ISO 15761-

2002

Steel Wedge, Gate, Globe and Check Valves, 2" and Smaller for the

Petroleum, Petrochemical and Allied Industries.

IS 1239 Part 1-2004 Mild Steel Tube.

IS 1239 Part 2-1992 Steel Tube Fittings.

IS 3589-2001 Steel Pipes for Water and Sewage Specification





7 Project Specifications

254624-400-SP-PIP-001 Piping Material Specification

254624-400-SP-PIP-018 Valve Material Specification

254624-400-SP-PIP-003 Specification for Painting : Piping

254624-400-PH-PIP-002 Tagging Philosophy for Piping Valves





Annexure VIII:

1 NON-DESTRUCTIVE TESTING REQUIREMENTS

In addition to the radiography requirements specifically identified in the valve data sheets,

radiography of valve castings shall be as applied below.

2 RADIOGRAPHY OF CARBON STEEL AND ALLOY STEEL CAST VALVES

Radiography procedure, areas of casting to be radiographed and the acceptance criteria shall be as

per ASME B16.34.

All castings shall be radiographic quality castings.

(a) Minimum requirement of radiography examination for all materials is as specified in individual

valve data sheets.

(b) Minimum additional radiography requirements for casting sizes for special/critical piping

classes (over and above the requirements covered in clause (a) above) as specified in individual

valve data sheets.

(i) Radiography procedure, areas of casting to be radiographed shall be as per ASME B16.34

and acceptance criteria shall be as per ASME B16.34 Annexure B. However for areas of

casting to be radiographed for types of valves not covered in ASME B16.34, vendor shall

enclose details of areas to be radiographed in line with ASME B16.34.

(ii) For random radiography wherever specified in individual data sheets, the sampling shall

be per size of the quantity ordered for each foundry.

(iii) Radiography wherever specified in the data sheets or as required above, shall be done by X-

ray to get the required sensitivity.

3 RADIOGRAPHY OF STEEL VALVES

Scope and specific requirements additional to those mentioned in Table 1 below, shall be as per

valve data sheets.





Table 1 - Non-Destructive Testing Requirements

Material Manufacturi

ng Method

Visual

Inspectio

n

Radiograph

y /

Ultrasonic

Inspection

Magnetic

Particle

Inspection

Liquid

Penetran

t

Inspectio

n

Liner

Spark

Test

Carbon Steel Casting &

Forging 100% N/A N/A N/A

DELETED DELETED

DELETED

Rad

iogra

ph

y e

xte

nt

as s

pec

ifie

d

in t

he

Tec

hn

ical

sp

ec f

or

Pro

cure

men

t o

f P

ipin

g I

tem

s

and

dat

a sh

eets

. DELETED

1.1 Refer to Table 2 and the Technical Specification for Procurement of Piping Items for NDE method

and acceptance criteria.

1.2 Fabricated valves and speciality piping components shall be fabricated in accordance with the

Specification for Welding of Pipes and Fittings.





Table 2 - NDE Method And Acceptance Criteria

NDE Method Standard Acceptance Criteria

Visual

Casting

Forging

MSS SP 55

ASME V Article 9

MSS SP 55

ASME V Article 9

Radiography

Casting

As specified in the Technical Specification for Procurement of Piping

Material

Ultrasonic

Forgings


Material

Magnetic Particle


Material

Where no standard is specified the following shall apply :

Casting &

Forging

ASME B16.34

APPENDIX II

ASME B16.34

APPENDIX II

Liquid Penetrant


Material

Where no standard is specified the following shall apply :

Casting &

Forging

ASME B16.34

APPENDIX III

ASME B16.34

APPENDIX III


PROJECT – WHITE OIL TERMINAL

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Annexure IX: Pressure Testing Requirements

Table 1

Valve

Type

Hydrotest

Body

(1.5 x DP)

Hydrotest

Seat

(1.1 x DP)

Hydrotest

Backseat

(1.1 x DP)

Pneumatic

Test Seat

(6 bar)

Disc Strength

Test

(1.5 x DP)

Ball 100% 100% N/A 100% N/A

Gate 100% 100% 100% 100% N/A

Globe 100% 100% 100% 100% N/A

Check 100% 100% 100% 100% N/A

Butterfly 100% 100% N/A 100% Valves 14”NPS &

Larger

Parallel

Slide 100% 100% 100% 100% N/A

Documents

TECHNICAL SUPPLY CONDITIONS FOR PIPING VALVEStenders.hpcl.co.in/tenders/tender_prog/TenderFiles/2513/Tender... · All piping components shall conform to the requirements of ASME B31