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SPECIFICATION FOR ACTUATED ON/OFF VALVES
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This document is the property of the client. It is confidential and all rights reserved, to client. Neither the whole nor any part of this document may be reproduced or transmitted without the prior written consent of the client to any third party. 4 3 2 1 0
04.09.2012 15.05.2012 03.03.2012
For Approval For Approval For Review
Rev.
Date
STATUS
B.Mobarrez B.Mobarrez B.Mobarrez Prepared
B.Mobarrez B.Mobarrez B.Mobarrez Checked CONSULTANT
E.Salimifar E.Salimifar E.Salimifar Approved
Approved CLIENT
Date
42” SOUR GAS TRANSPORTATION PIPELINE FROM SHAHID MONDANI‐ZADEH STATION TO BIDBOLAND‐1 REFINERY
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TABLE OF CONTENTS 1.
INTRODUCTION.....................................................................................................................................................................5
2.
APPLICABLE SPECIFICATIONS, CODES AND STANDARDS ....................................................................................5
3.
SITE CONDITIONS .................................................................................................................................................................8
4.
SUPPLIER SCOPE OF WORK AND RESPONSIBILITIES.............................................................................................9
4.1
GENERAL ............................................................................................................................................................................9
4.2
WARRANTIES ..................................................................................................................................................................10
4.3
LANGUAGE AND UNITS................................................................................................................................................10
5.
TECHNICAL SPECIFICATION .........................................................................................................................................11
5.1
BLOW DOWN VALVES (BDV) ......................................................................................................................................11
5.1.1
GENERAL ..........................................................................................................................................................................11
5.1.2
VALVES ..............................................................................................................................................................................11
5.1.3
VALVE SIZING .................................................................................................................................................................11
5.1.4
ACTUATORS .....................................................................................................................................................................11
5.2 ` 5.2.1
ESD VALVES .....................................................................................................................................................................12 APPLICATION ..................................................................................................................................................................12
5.2.2
REQUIREMENTS .............................................................................................................................................................12
5.2.3
VALVES ..............................................................................................................................................................................12
5.2.4
ACTUATORS .....................................................................................................................................................................12
5.3
PROCESS ISOLATING VALVES (XV) ........................................................................................................................13
5.3.1
GENERAL ..........................................................................................................................................................................13
5.3.2
VALVES ..............................................................................................................................................................................13
5.3.3
VALVE SIZING .................................................................................................................................................................13
5.3.4
ACTUATORS .....................................................................................................................................................................13
6.
ACTUATORS ..........................................................................................................................................................................14
6.1
GENERAL ..........................................................................................................................................................................14
6.2
AIR/GAS VOLUME TANK .............................................................................................................................................15
6.3
ACCESSORIES..................................................................................................................................................................15
6.4
SOLENOID VALVES .......................................................................................................................................................16
6.5
CABLE TERMINATION AND CONNECTION ..........................................................................................................16
7. 7.1
VALVE TYPE AND DESIGN ...............................................................................................................................................17 GENERAL ..........................................................................................................................................................................17
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7.2
VALVE CLASSES .............................................................................................................................................................17
7.3
RATING ..............................................................................................................................................................................17
7.4
SIZES ...................................................................................................................................................................................18
7.5
DIMENSIONS ....................................................................................................................................................................18
7.6
FLANGES ...........................................................................................................................................................................18
7.7
FLANGE DIMENSIONS ..................................................................................................................................................18
7.8
WELDING ENDS ..............................................................................................................................................................18
7.9
FIRE SAFE DESIGN.........................................................................................................................................................18
7.10
ANTI-STATIC DEVICES.................................................................................................................................................18
7.11
PRESSURE RELIEF .........................................................................................................................................................18
7.12
VENT AND DRAIN CONNECTION ..............................................................................................................................19
7.13
OPERATION ......................................................................................................................................................................19
7.14
LOCKING DEVICE ..........................................................................................................................................................19
7.15
POSITION INDICATOR ..................................................................................................................................................19
7.16
SEAT AND SEALS ............................................................................................................................................................19
7.17
SUPPORT ...........................................................................................................................................................................19
7.18 ELECTRICAL CERTIFICATION .................................................................................................................................19 ` 8. TEST & INSPECTION ..........................................................................................................................................................20 8.1
GENERAL CONDITIONS ...............................................................................................................................................20
8.2
GENERAL INSPECTIONS AND TESTS ......................................................................................................................21
8.3
SPECIFIC FUNCTIONAL TESTS .................................................................................................................................21
8.4
COMMON ..........................................................................................................................................................................21
8.5
REPORTS AND CERTIFICATES ..................................................................................................................................22
9.
PACKING & SHIPMENT .....................................................................................................................................................22
10.
INFORMATION & DOCUMENTS ................................................................................................................................23
11.
MARKING ..........................................................................................................................................................................24
12.
PAINTING ..........................................................................................................................................................................25
13.
RECOMMENDED SPARES ............................................................................................................................................27
14.
SPECIAL TOOLS..............................................................................................................................................................27
15.
QUALITY ASSURANCE .................................................................................................................................................27
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1. INTRODUCTION This specification covers the minimum requirements for design, fabrication, testing packing and shipment of Actuated On/Off valves for 42” Sour Gas Transportation pipeline form shahid Mondani‐Zadeh station to Bidboland refinery 1.1 Definition Client: I.G.E.D.C Contractor: EPC Contractor Supplier: the Company having a purchase order with the contractor for the supply of the specified equipment and associated services. Package vendor: The supplier of package equipment 1.2 APPRIVIATION: • LBV: Line Break Valve • `
• • • •
GOV :Gas over Oil Valve XV: Isolating Valve BDV: Blow Down Valve ESD: Emergency Shut Down FAT: Factory Acceptance Test
• • • •
ITP: Inspection Test Plan WPS: Welding Procedure Specification WPQ: Weld Procedure Qualification PQR: Procedure Qualification Records
2. APPLICABLE SPECIFICATIONS, CODES AND STANDARDS The equipment and accessories shall be designed, fabricated and tested in accordance to the
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following documents, codes, and standards. Codes and Standards (latest published issue or amendment shall apply unless otherwise stated.) ANSI: American National Standards Institute. ANSI‐B16.5: Pipe flanges and flanged fitting ANSI B16.34: Valves‐flanged and Butt welding ANSI B16.104: Control valve seat leakage ANSI B31.3: Code for pressure piping ANSI B16.10: Face‐to‐Face and, end‐to‐end dimensions of valves ANSI B16.25: Butt‐welding ends ANSI B31.4: Liquid transportation system for hydrocarbons, liquid Petroleum gas, anhydrous ammonia and Alcohols. ISO: `
International Standardization Organization ISO 15156(1, 2, 3) including Annex B; B.2.3: Petroleum and natural gas industries— Materials for use in H2S‐containing Environments in oil and gas production
ASTM: American Society for Testing and Materials. ASTM A435: Specification for straight‐beam ultrasonic examination of steel plates for pressure vessel. ASTM E 446: Reference radiographs for steel castings up to 2” (51mm) in thickness. ASTM 1457: Specification for PTFE Moulding and extrusion Materials ASME: American Society of Mechanical Engineers. ASME SECT. II: Welding rods and electrodes ASME SECTION VIII: Rules for construction of pressure vessels ASME SECT.IX: Qualification standard for welding procedure and welders
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British Standard
BS‐5351: Steel ball valve BS‐1560: Steel pipe flanges and flanged fittings for the petroleum Industry. EN: EN 50014 (BS 5501 Part 1): Electrical apparatus for potentially explosive atmospheres. General requirements EN 50018 (BS 5501 Part 5): Electrical apparatus for potentially explosive atmospheres. Flameproof enclosures “d”. EN 50019 (BS 5501 Part 6): Electrical apparatus for potentially explosive atmospheres. Increased Safety “e”. EN 50020 (BS 5501 Part 7): Electrical apparatus for potentially explosive atmospheres. Intrinsically safe “i” EN 50039 (BS 5501 Part 9): Electrical apparatus for potentially explosive atmospheres. Intrinsically safe “i” API: American Petroleum Institute API 6D: Pipeline Valves API 6F: Recommended practice for fire test for valves API 607: Fire Test for Soft seated Valves API 598: Valve inspection and test NACE: National Association of Corrosion Engineers NACE MR‐01‐75: Sulphide stress cracking resistance metallic material for oil field equipment..
IPS: Iranian Petroleum Standards IPS‐M‐PI‐110 Material and equipment standard for valves IGS: Iranian Gas Standard IGS‐M‐PL‐010‐1 Ball Valves , Class 150 , Part 1 IGS‐M‐PL‐010‐2 Ball Valves , Class 300 , Part 2 IGS‐M‐PL‐010‐3 Ball Valves , Class 600 , Part 3 IGS‐M‐PL‐010‐4 Ball Valves , Class 800 , Part 4 (ISO 17292) IGS‐M‐PL‐010‐5 Ball Valves,size 1/2 to 1.1/2 , part IEC: International IEC 529: Ingress protection for Electrical Apparatus
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MSS MSS‐SP‐6: Standard finishes for contact faces of pipe flange and connecting end flanges of valves and fittings. MSS‐SP‐44: Steel pipe line flanges MSS‐SP‐54: Quality standard for steel casting for valves, flanges and fittings and other piping components; Radiographic examination method. MSS‐SP‐55: Quality standard for steel casting for valves & flanges visual method. MSS‐SP‐61: Pressure testing of steel valves 3. SITE CONDITIONS For climatic condition please refer to doc No. FIBB‐01‐BD‐DBS‐PR‐0001. •
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•
• •
The equipment shall be tropicalised to eliminate mildew, fungi and other detrimental effects of a tropical environment, dust and moisture proof, fungus‐growth proof and resistant to dust and insect attack. Electronic circuit boards shall be suitably protected against corrosion and humidity by applying a protective coating, where deemed necessary by the Vendor. Packaging shall be suitable for shipment and storage under tropical conditions. The material shall be suitable for site condition and the Vendor shall design and provide proper material suitable for intended purpose. All electrical equipment shall be protected to IP65 as a minimum and finished to Vendor’s standard suitable for the environmental conditions. Particular attention shall be paid to. possible effects of corrosion, vibration, humidity, and extremes of temperatures.
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4. SUPPLIER SCOPE OF WORK AND RESPONSIBILITIES 4.1 General
2
1‐ The purpose of this specification is the minimum technical requirements for following valves that to be used for 42" gas transportation pipeline to Bidboland ‐1 refinery: -
ESD, Emergency Shut Down Valve BDV, Blow Down Valve XV , Isolating Valves The Actuated valves shall be the complete assembly, which includes the valve body and all pressure containing parts, pneumatic actuator, mounting yoke, accessories control station, solenoid valves, switches, push buttons, etc.
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2‐ The supposed valves shall be calculated / finalized by vendor. For detail information of normal operating condition refer to data sheets. 3‐ As a general the supplier is responsible for selection the suitable valves in accordance with above mentioned requirements and the specification mentioned in the requisition and its Attachments.
4‐ The valves shall be supplied fully assembled, ready for site installation, in such a way that only inlet/outlet lines connections been made at site. 5‐ Compliance by vendor with the provisions of this specification does not relive him of the responsibility to furnish equipment and accessories of proper design to meet the specified service condition as safe as possible. 6‐ Any recommendation from vendor to improve the safety/operation/design of the equipment will be reviewed and may be accepted when received with the proposal with sufficient justification. 7‐ The purchaser reserves the right to make changes in design during the manufacturing. Where such changes require the addition and/or deletion of material from those originally specified or additional design changes after approval of drawings, the cost thus resulting shall be charged or credited to the purchase. These costs shall be in accordance with the agreed price schedule.
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8‐ The manufacture shall be responsible for correcting free of charge any part of valves, which is not in accordance with the purchaser’s order and attached documents. 9‐ The manufacture shall advise the purchaser during design development, where in his opinion the valves and its accessories maybe liable to malfunction due to process/functional requirements. 10‐ Purchaser or his representatives are to be contacted for any ambiguity. 11‐ On all matters on which this requisition and its attached documents are silent; the purchaser’s written approval must be obtained. 12‐ All deviations from the requirements of any of the listed or attached Data sheets, Specifications, Codes, Standards, Regulations, Guidance Notes, etc, shall be agreed with the Owner before proceeding. 13‐ The supplier shall name and assign a qualified project manager to coordinate the supplier’s activities with the purchaser from placement of order to completion of project. 14‐ The project manager will provide a single point of contact between the purchaser and supplier. He shall be responsible for coordinating technical, commercial, service, and scheduling requirements of the valves supplying.
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4.2 Warranties The Supplier shall guarantee the valves; all valves and accessories shall be free from all defects in design, workman ship and/or materials. In case of any defect during installation, start‐up and /or guarantee period, he shall replace or correct the defected parts at his own expense including all transportation and labor cost. The valves shall have an operational guarantee of minimum one year from the date of operation or 18 months from the date of shipment whichever occurs first. 4.3 Language and Units English language shall be used in all documents and drawings. All units and measurements shall be in metric system (SI: International System of Units) except for piping sizes, which shall be in Inches.
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5. Technical specification 5.1 Blow Down Valves (BDV) 5.1.1 General Blow down Valves are used for depressurization resulting from selected shutdown levels where required. Vessels and equipment are depressurized in an emergency to reduce stresses in their metal and to minimize leaks that may occur as a result of mechanical failure. BDV’s shall have a minimum body size of 2” with tight shutoff (ANSI B16.104, class VI). 2 Process systems containing significant quantities of flammable fluid ;shall have provision for emergency gas and vapor de‐pressuring; designed to reduce pressure from initial conditions to 7 barg or 50% of design pressure (whichever is lower)whitin 15 miniutes. All valves will be actuated by the application of instrument Air/Gas supply following remote electrical signal to the solenoid valve(s). The operation of the valves shall be such that when a valve is caused to open by remote signal, it will remain open as long as it is not reset. The valves will be on/off; they will normally be fully closed, and open on demand. When closed they will be subject to high differential pressure and must provide tight shutoff. Valves shall be designed to open remotely form control room.
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5.1.2 Valves Blow Down valves shall be full bore ball valves sized according to the required blow down flow rate and pressure drop. Unless otherwise specified in the individual data sheets, valve type and design shall be as per this specification document. 5.1.3 Valve sizing Unless otherwise specified, BDV’s shall be line size. Care shall be taken to ensure that velocity through the valve body outlet shall not exceed 0.7 Mach as this may have detrimental effects on the flare piping. 5.1.4 Actuators Refer to actuator types section.
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Actuators shall be sized to open and close the valves at the maximum differential pressures and within the time, as specified in individual data sheets. Actuators shall be mounted on the valves. The design of the mounting arrangement shall be the responsibility of the valve Vendor. 5.2 ESD Valves 5.2.1 Application ESD Valves are used to isolate sections, one from another, under emergency conditions where required. These valves are used for isolation potentially hazardous flows of process fluids from one process system to another, as well as to the plant environment if containment is lost. The specific process condition will be shown on the individual valve data sheet. 5.2.2 Requirements
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ESD valves shall have the following characteristics as a minimum: - Ball valve - Actuator to close on air/Gas failure - Fire safe design - Tight shutoff (ANSI B16.104, class VI) - Manual reset facility, unless specified otherwise - Unless otherwise specified the valves shall be Air/Gas failure close type.
5.2.3 Valves Unless otherwise specified in the individual data sheets, valves shall be of the type and design as per this specification. 5.2.4 Actuators Refer to actuator section for actuator types. Actuators shall be sized to fully open and close the valves at the maximum differential pressures and within the time spans as specified in individual data sheets. Actuators shall preferably be Gas over oil powered by Actuating Gas supply, however in services where high torque requirements of ESD valves preclude the application of gas
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operated actuators, double acting hydraulically operated actuators with hydraulic power pack may be provided. Actuators shall be mounted on the valves. The design of the mounting arrangement shall be the responsibility of the valve Vendor. 5.3 Process Isolating Valves (XV) 5.3.1 General Process Isolating Valves are used for Purging ; Pressurizing;Vent and similar application during start up or normal shutdown. XV’s shall have a minimum body size of 2” with tight shutoff (ANSI B16.104, class IV). All valves will be actuated by the application of instrument Air/Gas supply following remote electrical signal to the solenoid valve(s). The valves will be on/off; their Normal position differs by application and shall comply to the relevant data sheet. When These Valves are closed they will be subject to high differential pressure and must provide tight shutoff.
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5.3.2 Valves Isolating valves shall be full bore ball valves sized according to the required blow down flow rate and pressure drop. Unless otherwise specified in the individual data sheets, valve type and design shall be as per this specification document. 5.3.3 Valve sizing Unless otherwise specified, XV’s shall be line size. Care shall be taken to ensure that velocity through the valve body outlet shall not exceed 0.7 Mach as this may have detrimental effects on the flare piping. 5.3.4 Actuators Refer to actuator types section.
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Actuators shall preferably be Gas over oil powered by Actuating Gas supply, however in services where high torque requirements of XV’s preclude the application of gas operated actuators, double acting hydraulically operated actuators with hydraulic power pack may be provided. Actuators shall be sized to open and close the valves at the maximum differential pressures and within the time, as specified in individual data sheets. Actuators shall be mounted on the valves. The design of the mounting arrangement shall be the responsibility of the valve Vendor. 6. ACTUATORS 6.1 General
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The following actuators shall be selected for ESDV and BDV: a) Single acting piston type, spring return with spring to close action for Air/Gas failure to close valves, and spring to open on Air/Gas failure to open valves b) Double acting piston type A single acting type actuator is preferred. Double acting actuators shall be used when Air/Gas supply pressure required for single acting type is greater than the minimum Air/Gas header pressure or when valve must remain in position in case of Air/Gas failure(fail lock position). Short stroke single acting pneumatic piston actuators shall preferably be used on emergency shutdown services. The actuators shall be powered by instrument Air/Gas supply. The actuators shall be sized in accordance with the maximum pressure drop specified in the data sheets and the minimum air/Gas header pressure of 4.0 bar(g). The actuators shall be able to operate at the maximum air/Gas pressure of 10 bar(g) and shall be tested at 1.5 times the maximum Air/Gas supply. At minimum supply pressure, the actuator torque/thrust shall be 25% above maximum torque/thrust required at maximum differential pressure across the valve. Unless otherwise specified, the maximum valve stroking time to achieve the safety position shall be defined according to size of the body (5 seconds for body up to 4”, 1 second per inch for body greater than 4”). A stroke speed setting facility in both directions shall be made available and performed by means of needle valve restricting power actuating fluid. Accessories such as solenoid valves, limit switches, etc., shall be installed directly on the actuator or on the body of the valve in order to minimize the valve overall time response. Actuators shall be supplied from one of the approve manufacturers which is listed and attached to this specification.
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6.2 Air/Gas Volume Tank Unless otherwise specified, all double acting actuators shall be equipped with an Air/Gas/Gas tank manufactured from carbon steel and calculated as per ASME VIII. The capacity shall be sized to permit 3 full valve strokes, where one stroke is open and close, in case of air/gas failure. 6.3 Accessories Accessories such electrical position switches, pressure pilots, pneumatic relays, etc. shall be supplied and mounted by the valve Vendor. a) Air/Gas filter regulator set – Each valve shall be supplied with a stainless steel filter regulator and pressure gauge fully tubed. b) The limit switches with EExd certified in hazardous area application shall be provided for remote position indication. Limit switches shall be mechanical type and snap acting hermetically sealed of precious metal suitable for zone 2, and contact rating shall be 2 Amp @ 24 VDC.
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c) The switches shall be wired to a valve mounted junction box and the wiring shall be protected by suitable weather proof and explosion proof flexible conduit. Cable entries shall be M20 x 1.5 ISO, proper for armored cables. Limit switches shall be mounted and tested at the factory. d) Tubing and fittings – Tubing material shall be 316SS. Fittings for air/gas piping shall be AISI 316 compression type, with double ferrule and complete with coupling nuts. 2
e) Hand wheel – Where specified in valves data sheets, a hand wheel shall be provided for valves(For Larg size valves Hand pump shall be provided) f) Position indicator – On/off actuators shall be provided with mechanical position indicator devices matching the two positions of the valve. g) ESD reset push button – shall be suitable for zone 2 and mounted on the front of the local control station. Contact rating shall be 2 Amp @ 24 VDC. h) These components and all others necessary facilities for the operation of the actuators shall form part of one assembly, completely tubed, wired and tested.
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6.4 Solenoid valves
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When the valve is equipped with solenoid valve, the following requirements shall be satisfied: The body material shall be 316 stainless steel , suitable for the environmental conditions and the service. Disc/seat material shall be resilient to give a tight shut off feature. Manual reset facility shall be provided as required in data sheets. Coil electric power supply shall be 24 VDC with maximum 12 Watt consumption. Solenoid valves shall be suitable for continuous duty equipped with manual reset, EExd certified in hazardous area application Two solenoids shall be provided for ESD and BDV valves where specified in data sheets. The solenoid valve that used for emergency shutdown function shall be provided with manual reset facilities and the other automatic reset from control system. Suppression diode to be provided for DC supply Internal and external earth terminal shall be provided for solenoid valves. Solenoid valves shall be equipped with cable glands in M20 x 1.5 for connection of armored cables: Solenoid valves shall be equipped with speed control knobs at their exhausts. Solenoid valve for ESD action shall be de‐energized to trip. Each solenoid valve shall be normally energized for normal operating position. However, their position, open or closed, when energized will be indicated in the individual data sheet. The assembly shall be housed in a weatherproof AISI 316 housing suitable for the specified hazardous area, and shall only require the connection of instrument air/gas supply and wiring of solenoid valves. Junction boxes shall be stainless steel, weather proof to IP 65 and the cable entry shall be M20 x 1.5, proper for armored cables. Additionally, in hazardous areas, electrical housing and junction boxes shall be explosion proof and all cabling/conduits etc. shall be suitable for explosion proof execution.
6.5 Cable Termination and Connection The actuators shall be equipped with two junction boxes designed to group the solenoid valves and the limit switches cables individually going to the same marshalling cabinet. For valves that two solenoids required two cable glands shall be provided for relative junction box. These junction boxes shall be provided with cable glands for all incoming and outgoing armored cables.
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Size of cable glands will be confirmed as soon as cables are fully designed. Junction boxes terminal blocks shall be of screwed type. 7. Valve type and design The characteristics of the valve bodies shall respect those defined in the following documents and as minimum the specification mentioned as follows: Specification for ball valves‐119‐GN‐000‐PD‐SPC‐1804 Also Design documentation shall be submitted for customer approval before commencement of manufacturing. 7.1 General -
Ball valves shall be in accordance with API‐6D. For trunnion‐mounted ball valves, each seat shall be self‐adjusting by means of a load spring and shall maintain contact with the ball.
Valves shall have split body (side or top entry that will be specified in relevant data sheet) design and provision shall be made to inject secondary sealant to maintain/improve seat tightness in the event a seat is damaged or otherwise leaking.
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Valves shall be double block and bleed in open & closed position.
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Type, body, ball, stem, seat and seal material and face‐to‐face dimension of all valves will be specified in purchase requisition.
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In services where the differential pressure over the valve results in a temperature drop which will cause freezing of the stuffing box and ice formation on the stem, extended bonnet shall be provided. Ball valves for 6” and larger shall be trunnion mounted.
7.2 Valve Classes Valves covered by this specification shall be furnished in the ANSI classes as specified on the data sheets. 7.3 Rating The maximum operating pressure rating of ANSI classes shall be in accordance with API‐6D table 2.1.
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7.4 Sizes All valves furnished to this specification shall be identified by the nominal valve size expressed in inches. Full‐bore valves when required will be specified in the data sheets. 7.5 Dimensions For flanged and weld end valves, face to face and end to end dimensions and tolerances shall be in accordance with API‐6D and ANSI B16‐10. 7.6 Flanges Where valves with flanged ends are required flanges may be integral or of welding neck type. Slip‐on flanges are not acceptable. Flanges shall be fully machined and for classes 150, 300, 600 & 900 shall be raised face. For class 1500 gasket contact surface shall be RTJ. Gasket contact surface finishing for all valves shall be in accordance with MSS‐SP‐6. 7.7 Flange Dimensions Flanges up to 24 inch, shall be in accordance with ANSI B 16.5 and 26″ and larger to MSS‐SP‐ 44.
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7.8 Welding Ends Butt welding ends shall be in accordance with ANSI B16.25 and ANSI B 31.4. The purchaser shall specify the inside diameter of welding ends. 7.9 Fire Safe Design All valves shall be fire safe and be capable of meeting the requirements of standards API 607, or API RP 6F as applicable. 7.10
Anti‐Static Devices All valves shall be fitted with an ANTI‐STATIC device.
7.11
Pressure Relief All valves shall be protected from overpressure in the body and/or bonnet cavity due to fluid thermal expansion. This protection shall be either by an appropriate assembly of the seats or by adding a relief valve. Where a relief valve is fitted on a buried installation, the relief valve should be located above ground.
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Vent and Drain Connection Vent & Drain connection shall be provided on 2 inch and larger valves and plugged with a steel plug threaded as per ANSI B2.1.
7.13
Operation The actuation of valves shall be in accordance with actuator specification mentioned in other sections. Where specified in valves data sheets, the valves shall be supplied with a single or double reduction worm gear operator handwheel in accordance with the Vendor’s standard. The gearbox shall be dust and weatherproof and filled with a suitable lubricant (Vendor shall specify the lubricant specification and its SAE No in his proposal)
7.14
Locking Device If valves with locking device specified in purchase requisition, valves shall be designed to accommodate a device for locking the valve in closed or open position.
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7.15
Position Indicator All valves shall be furnished with a valve position indicator, showing the open and closed position of the valve.
7.16
Seat and Seals Valve seats shall be bubble tight (as mentioned in relevant data sheets) in normal operation and renewable. Valve shall be suitable for repacking under pressure when fully open.
7.17
Support Support feet or leveling base shall be provided to facilitate leveling of valves during field installation where applicable.
7.18
Electrical Certification All electrical apparatus shall be certified to CENELEC or ATEX.
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8. TEST & INSPECTION 8.1 General Conditions -
Inspections and tests shall be performed during manufacturing on all equipment. The procedure (ITP)shall be in accordance with :
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‐Manufacturer and suppliers acitivity ‐Manufacturer and suppliers quality conrol plan ; including supervision of casting and forging manufacturer. to be submitted at least 6 weeks prior to inspection and testing for review and approval of customer and client. Tests shall only start after relevant Vendor drawings; test procedure and engineering data are received and approved as the final copies.(By Customer )
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The test procedure shall include leak tests of equipment and piping, tightness tests of instruments, electrical continuity tests, insulation tests, FAT test ;etc. Quality control procedure manual shall be available for client inspection and quality audits shall have admission to visit at any time.
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Design; Fabrication, inspection Certificates; certificate of conformity of valves; and testing documents shall be submitted to customer.
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Vendor shall perform inspections and tests at his works using his inspection and test facilities. Provided that the Inspection and test plan has been approved and inspection body has been authorized by customer.
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Where the inspections and tests be made at separate locations, due to sound technical reason, the Vendor shall notify the Contractor in his quotation.
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Contractor, Company or 3rd party inspectors shall be allowed to be involved in each and every
stage of inspections and shall be free to request any specify test included in the approved inspection and test procedure, The inspectors shall have access right to all facilities involved in the manufacturing of the equipment purchased under this specification.
In any case of waives, to witness the FAT in writing; Vendor shall provide the relevant test certificates with all test results.
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8.2 General Inspections and Tests
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Inspections and tests, as mentioned here, shall be carried out by the Vendor as a minimum. Each actuator shall be permanently installed on its respective valve, inspected and tested before shipment. Individual test certificate shall be issued. The test equipment shall simulate a typical valve load. Inspection and test certificates shall be submitted with final inspection book with authorized third party inspector approval. Inspections and tests shall include but not be limited to the following, which shall be carried out by the Vendor: ‐ Visual inspection ‐ Dimensional check ‐ Check of welding procedure (WPS;PQR&WPQ) ‐ Welding qualifications ‐ Impact and hardness tests ‐ Check of material certificates ‐ Radiographic, ultrasonic and other applicable non destructive examination tests ‐ Pressure tests, high and low pressure leak tests 8.3 Specific Functional Tests After successful completion of pressure tests, each valve shall be operated by the pneumatic operator a number of times to test the satisfactory operation of the valve and actuator combination. Individual test certificate shall be issued. Valves shall be caused to closed/opened by de‐energizing/energizing the solenoid valve(s). During the functional tests the correct setting and operation of the following components shall be verified as applicable: ‐ Solenoid valves ‐ Mechanical switches ‐ Trigger valves 8.4 Common ‐ Quality control and Quality assurance tests. ‐ General Inspections to include appearance, structure, dimensions, manufacture finish checks ‐ Wiring Tests
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8.5 Reports and Certificates -
The supplier shall furnish the purchaser with final book including the following test certificates and drawings:
a) Certificate of shop inspection. b) Welding procedure and welder qualifications & PQR c) Non‐destructive test certificates d) Certified reports giving chemical analysis and physical properties of steel and manufacturing process; Heat treatment and quality at level equal to ASTM specification. e) Hydrostatic test certificates f) Certified dimensions and sectional drawings. g) Certificate of conformity of valves with reference standards for design and fabrication. - Copies of all Vendor test reports shall be supplied by the Vendor before the Contractor or Company inspectors start to witness the performance tests. - For certified electrical instruments a copy of certificate and for listed electrical instruments list numbers and the name of the authorities shall be submitted. `
9. PACKING & SHIPMENT 1‐ Protection, packing, marking and dispatching are to be in accordance with Client instruction. 2‐ The vendor and any sub – vendor shall comply with the preservation and packing specification and the marking, documentation and dispatch instructions after satisfactory completion of all tests and inspections.
3‐ The vendor shall take all precautions deemed necessary for protection during shipment and additionally during storage in a marine environment including the following: The vendor shall supply a recommended procedure for long‐term outdoor storage (up to 12 months) with the quotation. Equipment shall be suitably packed including any dismantling, transit fastening and bracing necessary to prevent distortion or damage during shipment. Each individual carton or box shall be marked with the instrument tag number on the top and side of the carton. 4‐ Supplier shall submit the packing specification and the purchaser’s prior approval. No items of equipment shall be shipped without the purchaser’s prior approval. -
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10. INFORMATION & DOCUMENTS 1- The following items shall be provided by manufacturers at the stage of quotation/detail design (as mentioned in material requisition) for the perusal of purchaser.
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All calculations for valves and actuators Catalogues with exploded view diagrams Outline Drawings of valves and accessories. Dimensional Drawings of valves and accessories. Recommended spare parts list for Start‐up and commissioning Recommended spare parts list for two (2) years operation Wetted and non‐wetted parts per ASTM materials Material Certificates Test Reports and Certificates Installation procedure. Test procedure before installation and routine check procedures. Test report Operating procedure/ manual. RepAir/Gas& maintenance manual. 2- The Supplier shall provide, together with his quotation, a written response to all parts of this specification and relevant attachments. The section‐by‐section response shall be arranged in the same order with this specification and attachments. The Supplier shall state in his quotation that all of the requirements of this specification are met if no deviation is occurred. If any deviation occurs or if any service or item is not quoted, the reason for such exception or no bid with reference to appropriate section number, shall be clearly stated and possibly an alternative to be incorporated. “ Complies” (Refer to specification paragraph number). “Variation” (full explanation to be given). “ Enhancement” (full explanation to be given). “Option included at (stated) cost to be included with the commercial submission only “. 3- It is essential that all claims be substantiated by the Supplier with published specifications or firm guaranteed commitments. 4- The Supplier shall provide with his proposal a detailed quotation in regard to component part numbers, which shall be supported by specification sheets referring to those part numbers. 5- The Supplier shall clearly define the delivery schedule and milestones.
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6- All documents submitted shall have the project title, the supply Contract number and Supplier’s name clearly marked on each. 7- Unless specified otherwise, data required for commercial products or equipment shall show complete identifying data giving the Manufacturer’s name, type, model, size and characteristics of the product or equipment. Catalogue cut sheets shall not be acceptable. The data shall be comprehensive and shall fully demonstrate that all material or equipment specified shall meet the requirements of these specifications. 8- Applications drawings shall be drafted using AutoCAD version 2002 or later and free hand sketches shall not be acceptable.
9- All files of the documentation shall be provided on CD ROM support.
10- The Installation, Operating and maintenance manuals shall include all information required for these activities at site.
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11- FINAL Drawings, Documents and Data shall be complete with equipment tag numbers, stamped "Certified For Construction" and signed by a person authorized to bind the partnership or co‐ operation. If delivered equipment fails to conform to these drawings or documents. Supplier shall correct such failures to the satisfaction of Contractor at no cost to Contractor.
12- As‐built Drawings, Document and Data shall refer to those submitted to Contractor at the end of the job, and shall reflect the as‐fabricated and tested condition of the equipment. They shall meet the requirements of the project specification.
13- The Supplier shall submit its design, study reports, analysis, workshops drawings with bills of equipment and documents as listed in the requisition to the customer for review. The Customer shall return one print with his comments and/or review.
11. MARKING Each valve shall be furnished with a corrosion resistant nameplate, permanently fastened with drive‐screws and stamped as follows: Manufacturer’s name, model number, and serial number (valve and actuator) Valve action on air/gas failure Operating range Body and trim size (in inches) Body and trim materials Body and flange rating Instrument tag number in accordance with the individual data sheet
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Stroking time 12. PAINTING 1‐ The valves shall be blast cleaned to Swedish standard SIS 05‐56‐00 SA‐2‐1/2. Two coats of antirust shall follow this, to a dry film thickness of 70 microns or more. The finish and intermediate coats shall be of 50 and 100 microns dry film thickness respectively. (refer to below table) 2‐ All unpainted surfaces (inside and outside) shall be adequately protected with suitable antirust compound, easily removable by hydrocarbon solvent.
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ITEM
‐ METAL STRUCTURES - INSTRUMENTS - PIPING - EQUIPMENT
OPERATING TEMPERATURE (°C)
KIND OF PAINT SURFACE PREPRATION
T
