06.Standard Specification.pdf

of 3574

arei ENGINEERS5fgTar Rateg INDIA LIMITEDG.AUndenak.9)

STANDARD SPECIFICATIONFOR TANK LEVEL

INSTRUMENTS

STANDARD SPECIFICATION No.

6-52-0014 Rev. 3Pace 1 of 13

Ago 15:41 * fffg9114) q 1 kill

STANDARD SPECIFICATION FORTANK LEVEL INSTRUMENTS

3 12.12.11 Revised and Reissued as Standard Specification RP/JMS DM

2 31.03.06 Revised and Reissued as Standard Specification AM TGM PM VJN

1 15.01.82 Revised and Reissued as Standard Specification RK BRS RB AS

0 11.03.85 Issued as Standard Specification PVS TSN AKV AK

Standards Standards

Rev.No Date Purpose

Preparedby

Checkedby

CommitteeConvenor

BureauChairman

Approved by

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL All rights reserved

Page 2607 of 3574

OSPzieTENGINEERS

lai5legINDIA LIMITEDIA Go, of now unoortaknO/


INSTRUMENTS


6-52-0014 Rev. 3Page 2 of 13

Abbreviations:

AARHArithmetic Average Roughness Height

DCSDistributed Control System

DPDTDouble Pole Double Throw

MAWPMaximum Allowable Working Pressure

MgOMagnesium Oxide

NPTNational Pipe Thread

PTFEPoly Tetra Fluoro Ethylene

RIURemote Interface Unit

SPDTSingle Pole Double Throw

SSStainless Steel

RTDResistance Temperature Detector

Instrumentation Standards Committee

Convener:Ms. R. PriyamvadaMembers:Mr.P.K.Sahay

Mr.S.BhowalMr. M. NandiMs. R. Shanthi DeviMr. M.P Jain (Proj.)


Page 2608 of 3574

afdae?51g-iarialAtu,

ENGINEERSINDIA LIMITED


INSTRUMENTS


6-52-0014 Rev. 3Page 3 of 13

trt-)

CONTENTS

1.0GENERAL 4

2.0DESIGN AND CONSTRUCTION 6

3.0NAMEPLATE 13

4.0INSPECTION AND TESTING 13

5.0SHIPPING 13

6.0REJECTION 13

Format No. 8-00-0001-F1 Rev. 0 Copyright El L All rights reserved

Page 2609 of 3574

s'iltr oft ENCJNEERSINDIA LIMITED01. Go, ol India undertaking,STANDARD SPECIFICATION

FOR TANK LEVELINSTRUMENTS


6-52-0014 Rev. 3Page 4 of 13

1.0GENERAL

1.1Scope

1.1.1This specification, together with the data sheets covers the requirements for the design,materials, nameplate marking, inspection, testing and shipping of tank level instrumentscomplete with accessories.

1.1.2The related standards referred to herein and mentioned below shall be of the latest editionsprior to the date of the purchaser's enquiry:

ASMEAmerican Society of Mechanical Engineers.

1.20.1Pipe Threads General Purpose (Inch)16.5Pipe Flanges and Flanged Fittings16.20Metallic Gaskets for Pipe Flanges, Ring Joint, Spiral

wound and Jacketed.B 16.34Valves - Flanged, Threaded and Welding ends

API

American Petroleum InstituteMPMSManual of Petroleum Measurement Standards - Chapter 7.4

Static Temperature Determination Using Fixed AutomaticTank Thermometers

EN

European Standards

10204Inspection Documents For Metallic Products.

IS/IEC

Indian Standards/ International Electrotechnical Commission

IS/IEC 60079IS/IEC 60529IEC 61000-4

IEC 61158IEC 61158-2

IEC 61508

IEC 61511

Electrical Apparatus for Explosive Gas Atmospheres.Degree of Protection Provided by Enclosures (IP Code).Electromagnetic Compatibility (EMC) for IndustrialProcess Measurement and Control EquipmentFieldbus Standard for use in Industrial Control SystemPhysical Layer Specification and service definition forFieldbusFunctional Safety of Electrical/Electronic/ProgrammableElectronic Safety related Systems.Functional safety instrumented system for the processindustry sector

1.1.3In the event of any conflict between this specification, Job Specifications / data sheets,statutory regulations, related standards, codes etc., the following order of priority shallgovern:

Statutory Regulations

Job Specifications / Data Sheets

Standard Specification

Codes and Standards

1.1.4In addition to compliance to purchaser's specification in totality, vendors extent ofresponsibility shall include the following:

a)Purchaser's data sheets specify the minimum acceptable materials for the wettedparts such as gauge head, float/displacer, antenna, temperature element sensor,Isolation ball valve, calibration chamber etc. Alternate superior material ofconstruction shall also be acceptable provided vendor assumes completeresponsibility for the selected materials for their compatibility with the specifiedfluid and its operating conditions

Formal No. 8-00-0001-F1 Rev. 0 Copyright EIL All rights reserved

Page 2610 of 3574

16i1P-aelo7 fol9e^ ENGINEERSINDIA LIMITEDGovi pi India undenning) STANDARD SPECIFICATIONFOR TANK LEVELINSTRUMENTS STANDARD SPECIFICATION No.6-52-0014 Rev. 3Page 5 of 13

Selection of proper type of antenna for radar type of tank level instruments basedon the service and specified operating conditions.

Purchaser's data sheets specify the provision of still-well wherever envisaged. Itshall be vendor's responsibility to verify the adequacy of still-well for the offeredtank level instrument. Vendor shall also indicate the requirement of still-well fortanks/equipments where this is not indicated in the purchaser's data sheet.

1.2Bids

1.2.1

Vendor's quotation shall be strictly as per the bidding instructions to vendor attached withthe material requisition.

1.2.2

Whenever a detailed technical offer is required, vendor's quotation shall include thefollowing:

Compliance to the specifications.

Whenever the requirement of detailed specification sheet for tank level instrumentsis specifically indicated,a detailed specification sheetfor each tank levelinstrument shall be furnished, which shall provide all the details regarding type,material of construction for body/displacer/float, type of antenna, specification oftransmitter/ switch and accessories like ball valve, calibration chamber, multipointtemperature element, water probe, tank side indicator, remote interface unit etc. asapplicable. The material specifications and the units of measurement for variousparts in vendor's specification sheet shall be to the same standards as thoseindicated in purchaser's data sheet.

Special cable required, if any, along with cable specifications and maximumallowable cable length between tank level instrument and remote interface unit.

Proven references for each offered model of tank level instrument inline withclause 1.2.3 of this specification.

e)

A copy of approval from local statutory authority, as applicable such as Petroleum& Explosives Safety Organisation (PESO) / Chief Controller of Explosives (CCE),Nagpur or Director General of Mines Safety (DGMS) in India, for the electronicinstruments installed in electrically hazardous area along with:

Test certificate from recognised test house like Central Institute of Miningand Fuel Research (CIMFR) / Electronics Regional Testing Laboratory(ERTL) etc. for flameproof enclosure/intrinsic safety, as specified in the datasheet, as per relevant standard for all Indian manufactured equipments or foritems requiring Director General of Mines Safety DGMS approval.

Certificate of conformity from agencies like Laboratorie Central DesIndustries Electriques (LCIE), British Approval Service for ElectricalEquipmentinFlammableAtmospheres(Baseefa),FactoryMutual (FM), Physikalisch-Technische Bundesanstalt (PTB) , CanadianStandards Association (CSA), Underwriters Laboratories (UL) etc. forcompliance to ATEX directivesor other equivalent standardsfor allequipments manufactured outside India

0

Deviations on technical requirements shall not be entertained. In case vendor hasany valid technical reason, they must include a list of deviations tag number wise,summing up all the deviations from the purchaser's data sheets and other technicalspecifications along with the technical reasons for each of these deviations.

g)

Catalogues giving detailed technical specifications, model decoding details andother related information for each type of tank level instrument covered in the bid.

1.2.3All items, as offered, shallbe field proven and should have completed trouble freesatisfactory operation for a period of minimum 4000 hours on the bid due date in the similarapplication with the process conditions similar to those as specified in the purchaser's data


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Ofdae? ENGINEERS1a5tag INDIA LIMITED


INSTRUMENTS

STANDARD SPECIFICATION No.6-52-0014 Rev. 3

Page 6 of 13

sheets.Items with proto-type design or items not meeting provenness criteria specifiedabove shall not be offered.

1.2.4All documentation submitted by vendor including their quotation, catalogues, drawings,installation, operation and maintenance manual etc. shall be in English language only.

1.2.5Whenever specified, vendor must furnish certified values of failure rates, Probability offailure on demand (PFD) with test intervals for offered items for safety integrity levelanalysis.

1.2.6Vendor shall also quote for the following:

Two years operational spares for each level instrument and its accessories, whichshall include electronic modules, output meter, antenna, temperature element,measuring wire/tape, gaskets/o-ring, fuses etc. as a minimum.

Unit rate of any special cable.

c)Any special tools and tackles needed for maintenance work. In case no specialtools are necessary for maintenance for the offered level instruments, vendor mustcertify the same in their offer.

1.3Drawings and Data1.3.1Detailed drawings, data, catalogues and manuals required from the vendor are indicated by

the purchaser in vendor data requirement sheets. The required number of prints and softcopies shall be dispatched to the address mentioned, adhering to the time limits indicated.

1.3.2Final documentation consisting of design data, installation manual, operation andmaintenance manual etc. submitted by vendor after placement of purchase order shallinclude the following, as a minimum:

Specification sheet for each level instrument and its accessories.

Certified drawing for each level instrument which shall provide following details;

Orientation and distance between centre lines of connecting flanges (incase of mechanical float operated tank level instrument).

Overall dimensions of the complete top work instrument in millimetres.

Dimensions of displacer/float/antenna, water interface probe, temperatureelement, isolation ball valve and calibration chamber in millimetres.

Dimensions and mounting details of tank side instrument i.e. tank sideindicator, power on-off switch etc.

Still-well details, wherever required.

Clearance space required for maintenance work.

vii)Wiring diagram for the complete assembly including terminal numbers andcable type.

Copy of type test certificates

Copy of the test certificates for all tests indicated in clause 4.0 of this specification.

e)Installation procedure for tank level instruments.

0Calibration and maintenance procedure including replacement of its pans/internalswherever it is applicable.

2.0DESIGN AND CONSTRUCTION2.1General requirements2.1.1The type of tank level instrument shall be as specified in purchaser's data sheet and shall be

supplied complete with head mounted local indicator, transmitter and tank side indicators.Switch assembly shall be supplied when specified in purchaser's datasheet.


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Page 7 of 13

d012i ENGINEERSoa fame-, INDIA LIMITEDIA G" of inch Undela09/


INSTRUMENTS

2.1.2The tank level instrument shall be suitable for the design pressure and temperature specifiedin the purchaser's data sheets.

2.1.3Displacer/float of tank level instrument shall be designed considering;

The specific gravity of upper and lower fluids.

Design pressure/ temperature condition specified in the data sheets.

c)Internal diameter of the equipment nozzle and still-well.

2.1.4Unlessspecifically indicatedotherwise in the purchaser's data sheet, the material ofconstruction of tank level instrument shall be as follows as a minimum:

All wetted metallicparts like float, displacer, tape, wire, etc. shall be of 316 SS andsoft parts like seals etc. shall be of PTFE.

Instrument top work consisting of instrument flange and measuring chamber shallbe of stainless steel. Expander/ Reducer assembly, if required, shall also be ofstainless steel.

c)Electronics housing shall be metallic only, e.g. of anodised aluminium.

2.1.5Unless otherwise specified, the local digital readout provided at the gauge head and at tankside shall read in millimetre. All digital indicators shall have a test push button to check theillumination of all the seven segments of the indicator.

2.1.6Each level instrument shall be provided with a power on-off switch, which shall be locatednear the tank side indicator.

2.1.7In general, tank level instrument shall be configurable either from gauge head /tank sideindicator or from a separate configurator. Where separate configurator is required, vendorshall supply minimum two numbers of configurators unless otherwise specified in thepurchaser's datasheets. This requirement shall not be applicable for float operated tank levelinstruments.

2.1.8The design of electronic instruments shall be in compliance with the electromagneticcompatibility requirements as per 1EC 61000-4.

2.1.9End Connection

2.1.9.1Tank level instruments shall be flanged type with size and rating as specified in purchaser'sdata sheet.

2.1.9.2In case end connection of vendor's standard instrument is different than that specified in thepurchaser's data sheet, vendor shall include the required expander/reducer assembly in theirscope of supply.

2.1.9.3Unless otherwise specified, end connection details shall be as below:

Threaded end connections shall be to NPT as per ASME B 1.20.1.

Flanged end connections shall be as per ASME B 16.5.

c)Flange face finish shall be as per ASME B16.5. The face finish shall be as follows:

125 AARH:125 to 250 micro inch AARH

63 AARH:32 to 63 micro inch AARH

2.1.10Power Supply

Unless otherwise specified, the tank level instrument shall be suitable to operate atpower supply level of 110V / 230 V, 50Hz.

The supply voltage fluctuation of +10% and supply frequency fluctuation of 3Hzfrom the specified value, shall not affect the instrument performance.

2.1.11Whenever the purchaser's data sheet indicates the requirement of switch assembly, it shallmeet the following requirements:


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$8i1Pzi-e? F ENGINEERSf&Pag INDIA LIMITED

IA Cow of India undertaking)


INSTRUMENTS


Page 8 of 13

The switch assembly shall be integral to the gauge head/tank side indicator.

The switch assembly shall provide one set of DPDT (or two sets of SPDT)contacts.

Unless otherwise specified, the contacts shall be rated as follows:

For explosion proof application: 2A, 110V DC

For Intrinsically safe application: 0.5A, 30VDC

All switch contacts except those used in Intrinsically safe circuit shall be Silverplated. Switch contacts in Intrinsically safe circuit shall be suitable for theapplication.

The alarm set points shall be freely configurable.

2.1.12Terminal Housing

The terminal housing shall be suitable for the area classification indicated in thepurchaser's data sheets. Unless otherwise specified, the enclosure shall complywith the following requirements as a minimum:

Weather proof housing:IP 65 as per IEC 60529

Flameproof housing:Flameproof/Explosion proof i.e., Ex (d) as per IEC60079 for explosion proof construction

Flameproof housing shall also be made weather proof.

All cables shall terminate on the terminal blocks in all vendor supplied equipmentsincluding gauge head, tank side indicator, power switch, temperature element,water probe, transmitter etc. Separate terminal blocks shall be provided for powerand signal cables. Unless otherwise specified, terminals shall be suitable forterminating following conductor sizes, as a minimum:

Signal cables : 2.5 sq. mm

Power cables : 6 sq. mm

Separate terminal box shall be provided in case instrument terminals available asstandard are not suitable to accommodate the specified conductor sizes.

2.1.13Purchaser's data sheet specifies the size of still-well provided in the tank equipment. In case,vendor's standard product requires still-well size smaller than that specified, vendor shallinclude the supply of such still-well in their scope along with all mounting accessories, asnecessary, which shall fit into the specified still-well.

2.1.14Accessories and Interconnections

All accessories including mounting brackets required for installation of tankgauges and tank side indicator shall be supplied by vendor.

All signal cables/ power cable and related accessories like junction boxes, cableglands etc., required for interconnection between gauge head, tank side indicator,power on-off switch, multipoint temperature element and water probe etc. shall besupplied by the vendor. Unless specified otherwise , Signal or Power Cable oflength equal to Range/Height of the tank to be measured as indicated in therespective data sheet + Circumference of the respective tank + 15 meter shall besupplied by the vendor.

c)All junction/ terminal boxes, power on-off switches, cables glands etc. shall meetthe requirements specified in the clause no.2.1.12 (a) of this specification.

2.2Float Operated Tank Level Instruments

2.2.1Unless otherwise specified, float type tank level instrument typically shall have levelaccuracy of +2 mm.


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Ifaae?ENGINEERS

taiWtegINDIA LIMITEDSTANDARD SPECIFICATION

FOR TANK LEVELINSTRUMENTS


6-52-0014 Rev. 3Page 9 of 13

2.2.2Purchaser shall provide three (3) numbers of nozzles on the tank top each of 11/2" flangedwith rating as specified in the purchaser's data sheet. Vendor supplied instrument shall suitthe above nozzle sizes.

2.2.3The anchor bar shall be welded to the tank bottom. Instrument designed with unwelded solidWeights holding the guide wires taut at the tank bottom shall not be supplied.

2.2.4Springs of spring housing assemblies shall be cadmium or nickel plated, as a minimum.

2.2.5Where liquid seals have been specified, vendor shall select a suitable fill fluid which iscompatible with the process fluid.

2.2.6For tank level measurements in pressurised tanks/ equipments where purchaser's data sheetdoes not specify liquid seal, the tank side indicator shall have inbuilt sealing to avoid ingressof process vapours in the tank side indicator.

2.2.7Vendor shall be responsible to supply complete pipe work and related fittings from tank topto tank side indicator. The pipes shall be hot dip galvanised, as a minimum.

2.2.8Unless otherwise specified, the transmitter when specified shall provide 4-20 mA outputfrom the tank side indicator.

2.3Servo Operated Tank Level Instruments

2.3.1All servo operated tank level instruments shall be installed on a 6" flanged equipment nozzlewith 12" size still-well. The flange rating of the equipment flange shall be as per purchaser'sdata sheet.

2.3.2The requirement of isolation ball valve shall be specified in the respective data sheets.Unless specified other wise, the isolation valve shall be full bore ball type of 6" size.Minimum Body Wall Thickness shall not be less than specified in ASME BI6.34.

2.3.3Material of construction of drum housing/drum chamber compartment shall be stainlesssteel, as a minimum.

2.3.4Each servo level instrument shall be provided with a calibration chamber with a viewablewindow of blast proof glass. The calibration chamber can be either integral to theinstrument or separate. Whenever calibration chamber is separate i.e. not integral to the tanklevel instrument, the material of construction of calibration chamber shall be stainless steel.The calibration chamber shall also permit insertion / removal of displacer for maintenancewithout removing the instruments.

2.3.5Raising or lowering of displacer for calibration shall be possible on-line with the design ofstill-well indicated in the material requisition.

2.3.6As a standard, high and low level limit stop shall be provided to prevent the level sensorfrom being driven beyond the working range.

2.3.7The instrument measurement shall not be sensitive to pressure variation seen by theinstrument in the measuring chamber.

2.3.8It shall be possible to raise or lower the displacer remotely i.e. from tank side indicator.Where the level instrument is serially interfaced to remote interface unit, this facility shallalso be available at the remote interface unit.

2.3.9The servo type tank level transmitter shall be capable of providing the following outputs,

Serial output as per vendor standard protocol or field bus protocol as per IEC 61158.

Analogue 4-20 mA DC current output.

However, the output as required from the servo type level instrument shall be as specified inpurchaser's data sheet.

2.3.10The tank level instrument shall be capable of accepting input from multi element tanktemperature sensors (either thermocouple or resistance temperature detectors) and transmitthe same as a part of serial signal from the transmitter.


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lallaareT ENGINEERSsig7taiR, INDIA LIMITED STANDARD SPECIFICATIONFOR TANK LEVELINSTRUMENTS


6-52-0014 Rev. 3Page 10 of 13

The tank level instrument electronic shall automatically determine the average termperatureby identifying;

all the submerged elements in case of spot type sensors.

Longest fully submerged temperature element in case of variable length type sensor.

In case, the vendor standard tank level instrument does not meet this requirement separatefield mounted electronics shall be offered to meet this requirement.

2.3.11The servo level instrument shall be capable of measuring water level interface and productdensity. This data whenever required shall be transmitted as a part of serial signal.

2.3.12Performance Requirements

The accuracy of servo type of tank level instrument inclusive of linearity, repeatability andhysteresis shall be as follows:

Level accuracy shall bet 1mm over the entire tank height.

Density accuracy shall be +0.005gm/cc over the complete set density range.

2.4Radar type Tank Level Instrument2.4.1The type of antenna shall be as specified in the purchaser's data sheet. Where type is not

indicated in purchaser's data sheet, vendor shall select suitable type of antenna for thespecified process conditions including dielectric constant, viscosity and performancerequirements.

2.4.2Purchaser's data sheet indicates the nozzle size and rating of the equipment for radar type oflevel instrument. The size and rating of the tank level instrument shall be same as the tanknozzle requirement specified in the purchaser's data sheet.

2.4.3The radar type tank level transmitters shall be capable of providing following outputs:

Serial output as per vendor standard protocol or field bus protocols as per IEC 61158

Analogue 4-20 mA DC current output.

However, the output as required shall be specified in the purchaser's data sheets.

2.4.4The tank level instrument shall be capable of accepting inputs from averaging type of tanktemperature sensors (either thermocouple or resistance temperature detectors) and transmitthe same as part of serial signal.

The tank level instrument electronic shall automatically determine the average temperatureby identifying;

All the submerged elements in case of spot type sensors.

Longest fully submerged temperature element in case of variable length type sensor.

In case, the vendor standard tank level instrument does not meet this requirement separatefield mounted electronics shall be offered to meet this requirement.

In addition to temperature sensor inputs, the transmitter shall also be capable of acceptingwater probe input and pressure transmitter input, carry-out calculations and transmit thesignals as required, as part of serial interface.

2.4.5For pressurised liquified gas level measurement, if required, the tank level instrument shallhave a built in pressure transmitter to compensate for the pressure variations inside theequipment to maintain the performance requirement. Calibration pin shall be provided forthe on-line verification of the calibration of level instrument.


The accuracy of radar type of tank level instruments inclusive of linearity, repeatability andhysteresis shall be as follows:

a)Level accuracy shall be I mm over the entire tank height. Format No. 8-00-0001-F1 Rev. 0 Copyright EIL All rights reserved

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azdaeiENGINEERS$1=e-arINDIA LIMITED

(A 4o. of India Under miaow


INSTRUMENTS


Page 11 of 13

b)Level accuracy in case of pressurised liquified gases shall be +1.5 mm over the entiretank height.

2.5Remote Interface Unit (RIU)

2.5.1Remote interface unit shall be microprocessor based programmable device capable ofaccepting data from the tank level instruments over a serial network.

2.5.2The remote interface unit shall have a display unit and a keyboard for operation,maintenance and configurational requirements of tank level instrument.

2.5.3Remote interface unit shall facilitate the following operational requirements;

Communication between field level instruments and purchaser's host system.

Ensure data integrity through data security control.

c)Provide to display for the following:

Process parameters like level, temperature density and water interface asapplicable.

Diagnostic alarms of tank level instruments.

Command display for tank level instruments.

Mode display.

Separate personal computer shall be provided if the interface unit does not have built-in display and/or keyboard as per specifications.

Hoisting mechanism for servo type tank level instruments for verification of levelcalibration, density measurement and interface level measurement.

Calibration of any level instrument connected to the interface units.

2.5.4Interface unit shall provide a redundant MODBUS (RTU) with RS 485 serial output forinterface with host.

2.5.5Interface unit shall be supplied complete with all hardware and software capable ofmonitoring and system diagnostics. Zero checking of the level instruments shall also bepossible from remote interface unit.

2.5.6The interface units shall be supplied pre-installed and pre-wired in interface unit cabinetsunless specified otherwise in the material requisition.

2.6Tank-side indicator:

2.6.1Tank-side indicator shall provide a digital display and shall display the followinginformation:

Display for level, density and interface level, as applicable for the type of tank levelinstrument.

Average tank temperature when multipoint temperature elements are also installedalong with the tank level instrument.

c)Status of tank level instruments.

The parameter to be displayed shall be selectable from the tank side indicator or throughseparate hand held terminal.

2.6.2A test switch shall be available with tank side indicator to test the integrity of display.Where no switch is provided, the testing should be possible from a hand held terminal.

2.6.3Unless specifically indicated otherwise, both certified intrinsically safe or explosion prooftank side indicator shall be acceptable for hazardous area installation.

2.6.4Tank side indicator shall be suitable for 2" pipe mounting. Accessories required for pipeinstallation shall be supplied by the vendor.


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SW-4e? ENGINEERSIgate2eg WA LIMITED


INSTRUMENTS


6-52-0014 Rev. 3Pa e 12 of 13IA Can of India Uneenaking)

2.7Water Interface Sensor

2.7.1Whenever specified, vendor shall offer an independent water interface sensor which shall becapable of measuring interface between water and oil. An integrated water interface-cum-temperature probe shall be offered when specified.

2.7.2The water interface sensor/probe shall be suitable for the pressure and temperatureconditions specified in the purchaser's data sheet.

2.7.3The length of water interface level probe shall be as specified in the data sheet.

2.7.4Unless otherwise specified, the material of construction of wetted parts i.e. sensor/probe,insertion rope/wire etc. shall be SS 316, as a minimum.

2.7.5The water interface probe shall be top mounted with end connections as 2" flanged. Therating and type of flange shall be as specified in the data sheet.

2.7.6The sensor/probe shall have suitable anchoring facility to it straight and avoid its transversemovement.

2.7.7The sensor shall be connected to either tank level instrument electronics or to a separateelectronics as per vendor standard product.

2.7.8Performance Requirements:

The water interface measurement shall meet the following performance requirements:

Accuracy: 0.3% of full scale

Repeatability:f 0.1 % of full scale.

2.8Multi-element tank temperature sensor2.8.1Multi-element tank temperature sensor, when specified, shall be used for measurement of

average temperature in the equipment/tank. An integrated interface level-cum-temperatureelement shall be offered when specified.

2.8.2The multi-element temperature element shall be either multiple spot type or variable lengthtype. The type of temperature elements shall be as follows:

Spot type element:RTD type Pt100 or Thermocouple type E'

Variable length type elementRTD type Cu90

Other type of elements can also be offered provided they meet the performancerequirements specified in clause 2.8.8 of this specification.

2.8.3The length of the multi element temperature sensor shall be decided based on theequipment/tank height. However number of elements within the temperature sensor shallmeet the following requirements.

2.8.3.1Unless otherwise specified in the purchaser's data sheets, the number of temperatureelements in case of spot type multi-element temperature sensor shall be as follows:

The first element i.e. the bottom most element shall not be placed more thanI 000mm above the tank bottom.

All elements, other than the first element, shall be located typically at every 10% ofthe tank height with minimum and maximum distance between two successiveelements as 1000mm and 3000mm respectively.

2.8.3.2Unless otherwise specified in purchaser's data sheets, the number of elements in case ofvariable length type temperature sensor shall be provided based on the lengths indicated inTable 2 of API MPMS chapter 7.4.

2.8.4Each temperature element shall MgO filled with SS sheath. All elements within thetemperature sensor shall be bundled together within a flexible protection tube. The materialof construction of protection tube shall be SS 316, unless otherwise specified.


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sara-ae?51WirilLjteg

ENGINEERSINDIA LIMITEDIA CoN orUnderisongk


INSTRUMENTS


Page 13 of 13

2.8.5The end connections for the installation of temperature element on the equipment/Tank shallbe 2" flanged, unless otherwise specified, with rating and type as indicated in purchaser'sdata sheet. The flange material shall be SS 316, unless otherwise specified.

Provision of anchoring the free-end of the temperature element shall be provided either byproviding

Anchoring weights of suitable size. The material of construction of weights shall beSS 316, as a minimum.

Bolted anchor, when specifically indicated or whenever integrated water interface-cum-temperature sensor is specified.

2.8.6The temperature element shall be installed in a slotted still-well of 2" size.

Thermowell shall be provided, whenever specified. The material of construction ofThermowell shall be SS 316, as a minimum. Fill fluid shall be supplied wheneverThermowell installation is specified.

2.8.7The multi-element temperature sensor shall be connected to either tank level instrumentelectronics or to a separate electronics as per vendor standard product.


Unless otherwise specified the multi-element temperature sensor shall have a measurementaccuracy of +0.5 degC throughout its measurement range.

3.0NAMEPLATE3.1Each tank level indicator shall have a stainless steel nameplate attached firmly to it at a

visible place, furnishing the following information:

Tag number as per purchaser's data sheet.

Manufacturer's serial number and model number.

Manufacturer's name/trade mark.

Range of level measurement in millimetres.

e)Nominal end connection size in inches and rating.

1)Area classification in which the equipment can be used.

g)Hazardous area certificate number.

4.0INSPECTION AND TESTINGPurchaser reserves the right to inspect and witness testing of all the items at the vendor'sworks in line with the inspection test plan and approved quality documents for tank levelinstruments. All these tests shall be completed by the vendor and test reports shall besubmitted to Purchaser for scrutiny.

5.0SHIPPING5.1All threaded and flanged openings shall be suitably covered to prevent entry of foreign

material.

5.2All the items comprising a tank level indicator system shall be individually packed andshipped in the same crate.

6.0REJECTION6.1Vendor shall prepare their offer strictly as per clause 1.2 of this specification and shall attach

only those documents, which are specifically indicated in the material requisition.

6.2Any offer not conforming to the above requirements, shall be summarily rejected.


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15tiftesige..1105teg

IAKIi Pi2a52051JMAI

ENGINEERS STANDARD SPECIFICATIONINDIA LIMITED FOR CONTROL VALVESIA Govt of India Undertaking)


Page 1 of 20

W*0' ciircil*fffR 411141 raMkiiSTANDARD SPECIFICATION FOR

CONTROL VALVES

3 11.04.11 Revised and Reissued as Standard Specification MN

2 15.02.07 Revised and Reissued as Standard Specification SM

1 01.11.96 Revised and Reissued as Standard Specification RK

0 11.03.85 Issued as Standard Specification PVS

Rev.No Date Purpose

Preparedby

TGM HCJ VC

BRS RB AS

TSN AKV AK

Standards StandardsChecked Committee Bureau

by ConvenorChairman Approved by


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31e-11 lai5reg1.17MMMIF tr,f3M7.1)

ENQNEERS STANDARD SPECIFICATIONINDIA LIMITED FOR CONTROL VALVESIA Govt Of India Undertaking)


6-52-0031 Rev. 3Page 2 of 20

Abbreviations:

AARH Arithmetic Average Roughness Height

CIMFR Central Institute of Mining and Fuel Research

EDDL Electronic Device Description Language

ERTL Electronics Regional Testing Laboratory

FDT/DTM Field Device Tool/Device Type Manager

FF Fieldbus Foundation

FISCO Fieldbus Intrinsic Safety Concept

HART Highway Addressable Remote Transducer

HHT Hand Held Terminal

NACE National Association of Corrosion Engineers

NPS Nominal Pipe Size

NPT National Pipe Thread

PID Proportional, Integral and Derivative

PTFE Poly Tetra Fluoro Ethylene

SS Stainless Steel

TSO Tight Shutoff

Instrumentation Standards Committee

Convener: Ms. R. PriyamvadaMembers: Mr.P.K.Sahay

Mr.S.BhowalMr. M. NandiMs R Shanthi DeviMr. M.P. Jain (Proj.)

Format No. 8-00-0001-F1 Rev. 0

Copyright EIL - All rights reservedPage 2629 of 3574

ei ENGINEERS STANDARD SPECIFICATIONge.,. faffieg INDIA LIMITED FOR CONTROL VALVES(A Gout of India Undertaiong)


6-52-0031 Rev. 3Page 3 of 20

lannnf ivosreanavara)

CONTENTS

1.0 GENERAL 4

2.0 DESIGN AND CONSTRUCTION 9

3.0 NAMEPLATE 20

4.0 INSPECTION AND TESTING 20

5.0 SHIPPING 20

6.0 REJECTION 20

ANNEXURES:

ANNEXURE - 1: STUD-BOLT AND NUT MATERIAL REQUIREMENT

ANNEXURE - 2: GASKET MATERIAL REQUIREMENT


Copyright El L All rights reservedPage 2630 of 3574


6-52-0031 Rev. 3Page 4 of 20wren eigag7airJodrall

ENGINEERS STANDARDOge_li 'Meg INDIA LIMITED FOR CONTROL VALVES

SPECIFICATIONIA Gov) or Ida Undertaking)

1.0 GENERAL

1.1 Scope

1.1.1 This specification, together with the data sheets describes the requirements for the design,materials, nameplate marking, inspection, testing and shipping of control valves.

1.1.2 The related standards referred to herein and mentioned below shall be of the latest editionsprior to the date of the purchaser's enquiry;

ASME American Society of Mechanical Engineer.

1.20.116.516.20

16.3416.47-B

Pipe Threads, General Purpose (Inch)Pipe Flanges and Flanged FittingsMetallic Gaskets for Pipe Flanges, Ring Joint, Spiral woundand Jacketed.Valves flanged, Threaded and Welding End.Large Diameter Steel Flanges

ANSI/FCI American National Standard Institute/Fluid Control InstituteFCI 70-2 Control Valve Seat Leakage

API American Petroleum Institute

6 D Pipelines valves (Gate valve, Plug, Ball and Check valves)598 Inspection Requirements609 Lug and wafer type, Butterfly valves.

AWWA American Water Works Association - Steel Pipe Flanges For Water WorksC207 CL.D Services

BS British Standards

6364 Valves in cryogenic service

EN European Standards

10204 Inspection Documents For Metallic Products.61056-1 Specification for performance, design and construction of

valve,regulated sealed type.

IBR Indian Boiler Regulation.

IS/IEC Indian Standards/International Electro-Technical Commission

IS/IEC 60079 Electrical Apparatus for Explosive Gas Atmosphere.IS/IEC 60529 Degree of Protection Provided by Enclosures.IEC 60534-3-2 Face to Face dimension of rotary valves except butterfly

valves.IEC 60534-4 Seat leakageIEC 60534-8.3 Industrial process control valves, noise consideration,

control valve aerodynamic noise prediction methodIEC 60534-8.4Industrial process control valves, noise consideration,

prediction of noise generated by hydrodynamic flowIEC-61158 Fieldbus Standard for use in Industrial Control SystemIEC-61158-2 Physical layer specification and Service definition for

Field bus

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL All rights reservedPage 2631 of 3574

Inligar fait5reg

I. 71 Ni'A EaA JOilS31)

ENGINEERSINDIA LIMITEDA Gov/ of India Uncle/Wong/

STANDARD SPECIFICATIONFOR CONTROL VALVES

STANDARD SPECIFICATION No.(tErl 6-52-0031 Rev. 3

Page 5 of 20

FF 890 Function Block Application Process Part 1FF 891 Function Block Application Process Part 2FF 892 Function Block Application Process Part 3FF 893 Function Block Application Process Part 4FF 894 Function Block Application Process Part 5IEC 61508 Functional Safety of Electrical/Electronic/Programmable

Electronic Safety related Systems.IEC-61511 Functional safety instrumented system for the process

industry sectorIEC-61804 Function Blocks (FB) for Process Control: Electronic

Device Description

ISA

International Society of Automation

75.01.0175.02TR75 .0475.05.0175.07

75.08.01

75.08.02

75.08.04

75.08.05

75.08.06

75.11.01

75.19.0175.22

75.25.01

TR 75.25.0275.13

75.17RP75.23

Flow equation for sizing control valves.Control valve capacity test procedure.Control Valve positioner stabilityControl Valve terminologyLaboratory measurement of aerodynamic noise generatedby control valvesFace to face dimensions for integral flanged Globe-stylecontrol valve bodies (ASME Class 125,150,300 and 600)Face to face dimensions for flangeless control valve(ASME Class 150,300 and 600)Face to face dimensions for Buttweld-end globe stylecontrol valve (ASME Class 4500)Face to face dimensions for Buttweld-end globe stylecontrol valve (ASME Class 150,300,600,900,1500 and2500)Face to face dimensions for flanged Globe-style controlvalve bodies (ASME Class 900,1500 and 2500)Inherent flow characteristic and Rangeability of controlvalves.Hydrostatic testing of control valves.Face to centre-line dimensions for flanged Globe-styleAngle control valve bodies (ASME Class 150,300 and600)Test Procedure for Control valve response measurementfor step inputsControl valve response measurement for step inputsMethod of evaluating the performance of positioners withanalog input signals and pneumatic output.Control valve aerodynamic noise prediction.Considerations for evaluating control valve cavitation

ITK

Interoperability Test Kit (latest version)

MSS

Manufacturer's Standardisation Society

SP25 Standard Markings System for Valves, Fittings, Flanges andUnions

NACE

National Association of Common Engineers

MR0103

Materials Resistant to Sulphide stress cracking in CorrosivePetroleum Refinery Environments


Copyright EL All rights reservedPage 2632 of 3574

$igai fit54-jeUlairenerroxr CM J,R101)

ENGINEERS STANDARD SPECIFICATIONINDIA LIMITED FOR CONTROL VALVESIA Gov/ of India undertaking)


6-52-0031 Rev. 3Page 6 of 20

OSHA Occupational Safety and Health Authority

1.1.3 In the event of any conflict between this standard specification, job specifications/datasheets, statutory regulations, related standards, codes etc., the following order of priorityshall govern:

Statutory regulations

Job Specifications/Data Sheets

Standard specification

Codes and standards

1.1.4 In addition to meeting purchaser's specifications in totality, vendors' extent of responsibilityshall also include the following:

Purchaser's data sheets specify the minimum acceptable materials for the controlvalve body and trim. Alternate superior materials of construction shall also beacceptable provided vendor assumes complete responsibility for proper selection ofmaterial for these parts for their compatibility with the process fluid and itsoperating conditions.

Purchaser's data sheets specify the control valve size, flow coefficient (Cv) andrequired flow rangeability. Vendor shall be responsible for selecting theirstandard valve flow coefficient suitable for the specified service and processconditions specified in the purchaser's data sheets.

Selection of actuator to meet the shut off differential pressure indicated in thepurchaser's data sheets.

Checking for cavitation, flashing and noise generated and provide suitable trimand treatment to limit these within appropriate limits.

1.2 Bids

1.2.1 Vendor's quotation shall be strictly as per the bidding instructions to vendor attached withthe material requisition.

1.2.2 Whenever a detailed technical offer is required, vendor's quotation shall include thefollowing:

Compliance to the specifications.

Whenever specifically indicated, a detailed specification sheet for each controlvalve which shall provide information regarding type, material of construction,capacity etc. of the control valve and its valve accessories. The materialspecifications and units of measurement indicated in the specification sheet shallbe to the same standards as those in purchaser's data sheet.

c) Whenever the requirement of sizing calculation is specifically indicated in thematerials requisition, vendor shall furnish sizing calculation for each tag numberclearly highlighting the standard used for calculation, noise level, cavitation orflashing, Cv selected, percentage opening at minimum, normal and maximumflow, inlet and outlet velocity etc.


Page 2633 of 3574

ENGINEE RS STANDARD SPECIFICATION1gal Oa& INDIA LIMITED FOR CONTROL VALVES

IA Gov/ of India undertakog)


6-52-0031 Rev. 3Page 7 of 20

14271 evecnie 4,390.1)

Proven references for each offered model in line with clause no. 1.2.3 of thisspecification specifically for valves with ASME Class 600 and above, temperaturemore than 250C and below-29C, pressure drop greater than 50 kg/cm 2 andspecial application like hydrogen, NACE ,Cryogenic etc.

A copy of approval for items such as limit switches, solenoid valves, electro-pneumatic converters, electro-pneumatic positioners, smart positioners ,Fieldbuspositioners from local statutory authority, as applicable, such as Petroleum AndExplosives Safety Organization (PESO)/Chief Controller of Explosives, Nagpur(CCE) or Director General of Mining Safety (DGMS) in India, along with:

Test certificate from recognised test house like Central Institute of Miningand Fuel Research (CIMFR) / Electronics Regional Testing Laboratory(ERTL)etc. for flameproof enclosure and/ or intrinsic safety, as specifiedin the data sheets as per relevant Indian Standard for all Indianmanufactured equipments.

Certificate of conformity from agencies like Laboratorie Central DesIndustries Electriques (LCIE), British Approval Service for ElectricalEquipment in Flammable Atmospheres (Baseefa), FactoryMutual (FM), Physikalisch-Technische Bundesanstalt (PTB), CanadianStandards Association (CSA), Underwriters Laboratories (UL) etc., forcompliance to ATEX directives or equivalent recognised standards for allequipments manufactured outside India.

Limitation, if any, in changing actuator orientation at site.

Deviations on technical requirements shall not be entertained. In case vendor hasany valid technical reason, they must include a list of deviations tag number wise,summing up all the deviations from the purchaser's data sheets and other technicalspecification along with the technical reasons for each of these deviations.

h)

Catalogues giving detailed technical specifications, model decoding details andother information for each type of control valve and accessories covered in the bid.For fieldbus positioners, information shall include, but not limited to, productcertification, power supply, current drawn, Standard/Advanced/Enhanced functionblocks available and the execution time for each block, device type, number of linkobjects, Virtual Communication Relationships, Basic and advanced diagnosticfeatures, failure mode etc.

1.2.3 For valves in cryogenic service, vendor shall meet the following acceptance criteria:

a)

Vendor shall furnish, along with the offer, type test certificate, duly witnessed byThird Party Inspection agency like M/S LRIS, DNV BV, TUV, CELL etc. of havingsuccessfully conducted the cryogenic test as per BS 6364 on the offered valves(same model, size, rating and material) in cryogenic service. Further vendor to notethe following:

Test temperature shall be -45 C for LTCS and -196 C for all grades of austeniticStainless Steel.

Test carried out on a particular size of one type of valve, pressure rating andmaterial shall qualify all sizes equal to and below the test valve size for the sametype, pressure rating and material. In case of austenitic Stainless Steel any onegrade would qualify for other grades of austenitic Stainless Steel.


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401fReit4 ENGINEERS STANDARD SPECIFICATION.Self Eiffreg INDIA LIMITED FOR CONTROL VALVES

IA Gov! o India Undertaking)


6-52-0031 Rev. 3Page 8 of 20

b) In case vendor does not have cryogenic type test certificate for the offered valves asmentioned above, vendor shall confirm to conduct the cryogenic test on the offeredvalves and furnish type test report meeting requirements specified in Clause 1.2.3a) above.

Vendor must have proven references as per clause 1.2.4 of this specification foreach of the offered valves (same model, size , rating and material) in cryogenicservice. The references with details shall be furnished with the offer.

In case the vendor fails to conduct cryogenic test(s) within 12 weeks or failure inthe test(s) conducted after receipt of order, the purchaser reserves the right toinvoke any of the provisions of the purchase order including cancellation of thePurchase Order at the risk and cost of vendor.

1.2.4 All items, as offered, shall be field proven and should have been operating satisfactorilyindividually for a period of minimum 4000 hours on the bid due date in the processconditions similar to those as specified in the purchaser's data sheets. Items with proto-typedesign or items not meeting provenness criteria specified above shall not be offered.

1.2.5 Whenever specified, vendor must furnish certified values of failure rates, probability offailure on demand (PFD) and test intervals for the safety integrity level (SIL) analysis.

1.2.6 All documentation submitted by the vendor including their quotation, catalogues, drawings,installation, operation and maintenance manuals etc., shall be in English language only.

1.2.7 Vendor shall specifically note that the quote for control valves shall include the following:

One extra set of packing and bonnet gasket with each tag.

One extra set of stem seal 0-ring for each actuator and piston 0-ring additionallyfor each piston actuated valve.

c) Line bolting (set of studs and nuts) and set of gasket, in case of flangeless valves asper material given in Annexure-1 and Annexure-2 with each such tag number.

1.2.8 Vendor shall separately quote for the following:

Control valve diagnostic package for seat ring, gland packing and actuatordiagnostic with smart positioner when specified.

Two years' operational spares for offered control valve and its accessories, whichshall include plug, seat ring, gasket set, packing set, diaphragm/o-ring set etc. as aminimum.

c) Any special tools needed for maintenance work. Vendor must certify in their offerin case no special tools are necessary for the offered control valves and theiraccessories.

1.3 Drawing and Data

1.3.1 Detailed drawings, data, catalogues and manuals required from the vendor are indicated bythe purchaser in vendor data requirement sheets. The required number of reproducible,prints and soft copies should be dispatched to the address mentioned, adhering to the timelimits indicated.

1.3.2 Final documentation consisting of design data, installation manual, Technical catalogues,operation and maintenance manual etc., submitted by the vendor after placement of purchaseorder shall include the following, as a minimum:


Page 2635 of 3574

t31 ENGINEERS STANDARD SPECIFICATIONIA

lear lagleg INDIA of India Undert

DIA LIMITED FOR CONTROL VALVESakog)


6-52-0031 Rev. 3Page 9 of 201.11E71 ...rave tE1.3.701131

Specification sheet for each control valve, positioner and other accessories andsizing calculation.

Certified drawings for each control valve and its accessories, which shall providedimensional details (face-to-face and height of completely assembled valve).Dimensions of clearance space for maintenance work, weight of completelyassembled valve, internal constructional details, materials of construction ofactuator, wiring diagram, orientation with respect to flow direction marked on thebody.

Copy of the type test certificates.

Copy of the test certificates for all tests indicated in Inspection Test Plan.

e) Installation procedure for control valves and their accessories.

0 Calibration, configuration and maintenance procedures including replacement ofits parts/ internals wherever applicable.

Control valve operating signatures whenever smart positioners or field bus basedpositioners are specified.

Device Descriptor (DD) Files for configuring Smart positioner /Fieldbusparameters

i) Common File Formats (CFF) for integrating the fieldbus positioner into the controlsystem.

2.0 DESIGN AND CONSTRUCTION

2.1 Body

2.1.1 Control valves shall have flanged end connections integral to the valve body. Split body typevalve design shall not be offered unless specifically indicated in the purchaser's data sheets.Whenever flangeless control valve body design is specified in the purchaser's data sheet,following shall apply:

Wafer type or lug type body design for control valves body size up to 6 inches.

Lug type body design for butterfly type of control valve body size more than 6inches.

2.1.2 The minimum control valve body size shall be 1 inch. Control valve body size of less than 1inch shall be offered only when specifically indicated in the purchaser's data sheet.

2.1.3 The valve body rating should be equal to or higher than the flange rating specified in thedata sheets. As a minimum, control valve body shall be rated for ASME Class 300.However, end connection shall be as specified in purchaser's data sheet.

2.1.4 The control valves shall be suitable for installation in horizontal as well as in vertical lines.

2.1.5 For all applications, where full port valves are specified, following shall apply:

Port size shall be equal to line size for rating up to ASME Class1500.

Port size shall not be smaller than one size lower than that of the line size for bodyrating ASME Class 1500 and above.


Page 2636 of 3574

RelOgaliataft

I.Ern riecmeas.737.3)IA Govt of India Undertaking)

ENGINEERS STANDARD SPECIFICATIONINDIA LIMITED FOR CONTROL VALVES


6-52-0031 Rev. 3Page 10 of 20

2.1.6 Flow Direction

2.1.6.1 In general, flow direction shall be as below:

Flow tending to open for single seated unbalanced valve design.

Flow entering between the seats for double seated valves.

c) Flow entering at the side and leaving at the bottom for angle valves.

For valves design other than those specified above, flow direction shall be as permanufacturer standard.

2.1.6.2 Flow direction shall be clearly marked on the control valve body.

2.1.6.3 For 3-way control valves, service like mixing or diverting, shall be clearly identified withinlet and outlet end connection clearly marked on the control valve body.

2.1.7 End Connections

2.1.7.1 Unless otherwise specified, the following shall govern::

Threaded end connections shall be to NPT as per ASME B 1.20.1.

Flanged end connections shall be as per ASME B 16.5/ B 16.47B/ AWWAA C207CL.D.

Flange face finish shall be as per ASME B 16.5. The face finish shall be as follows:

125 AARH : 125 to 250 micro inch AARH

63 AARH : 32 to 63 micro inch AARH

Grooves of ring type joint flanges shall be octagonal as per ASME B 16.20

2.1.7.2 Face-to-face dimensions of globe type control valves shall be in accordance with ISA 75.08.

2.1.7.3 Where provided, control valve bottom drains shall be plugged off or blind flanged. Where aplug is used, threads shall correspond to ASME B 1.20.1 (NPT). Where a flange is used, itsdimensions and rating shall correspond to ASME B 16.5.

2.1.8 Material of Construction

2.1.8.1 The material of construction of control valves shall be as specified in the data sheet. Nomaterial shall be substituted by vendor without specific written approval from purchaser.

2.1.8.2 Control valve body, bonnet, bottom flange, line flanges and other pressure containingassemblies shall be of the same material of construction as specified for valve body in thepurchaser's data sheets.

2.1.8.3 The bonnet flange and bottom flange shall have metallic spiral wound gaskets suitable forthe specified service. The gaskets with asbestos bearing fillers shall not be used.

2.1.8.4 Vendor shall be responsible for selecting proper material for the internal parts of controlvalve. All such materials shall have the same or better specification than specified in thepurchaser's data sheets.


Page 2637 of 3574


6-52-0031 Rev. 3Page 11 of 20 !AIR?, elecnie 3.1,171)

01c4el ENGINEERS STANDARD SPECIFICATION1i Ogreg INDIA LIMITED FOR CONTROL VALVES

(A Govt of lndu Undertaking)

2.1.8.5 The material of construction of silencers, diffuser plates, diffuser plate assembly etc shall beas per the body material specified in the purchaser's data sheets, as a minimum.

2.2 Trim

2.2.1 The term 'trim' covers those parts of valve assembly (excluding the body, bonnet andbottom flange) which are exposed to and ard in contact with the line medium consisting ofbut not limited to the seat ring, valve stem, valve plug, valve plug guide, guide bushing andcage.

In case of rotary type of control valves like butterfly, ball, segmental ball, rotary plug,eccentric disc and rotary disc, the term trim covers disc/ball, seat ring, shaft and bearing.

2.2.2 Guiding

2.2.2.1 Single seated globe (unbalanced) and angle type control valves shall have heavy top plugguiding. Stem guided control valve design shall not be acceptable unless specificallyindicated in datasheets.

2.2.2.2 Single seated globe (balanced) control valves shall be of cage guided design. The cage shallprovide a continuous plug guiding.

2.2.2.3 Double seated valves shall have top and bottom or cage guiding and shall be of the pressurebalanced type.

2.2.2.4 Whenever cage type control valves are specified, top guided or top and bottom guidedcontrol valves can be offered provided it meets all other process and functionalrequirements. But whenever top or top and bottom type of guiding is specified, cage typecontrol valves shall not be offered.

2.2.2.5 3-way control valves of either diverting or mixing type shall have top guiding.

2.2.2.6 Rotary control valves like butterfly, segmental ball, eccentric rotary plug etc shall haveblowout proof shaft guiding design.

2.2.2.7 Guide bushings shall be of a sufficiently hard material to resist side thrust on the plug.

2.2.3 Trim Design

2.2.3.1 Control valve manufacturer/vendor shall be responsible for trim selection and trim design ofthe control valve. However it must meet the following minimum requirements:

Control valve trim design shall suit the type of guiding specified in the data sheet.

The trim design and material of construction shall be selected to minimize the riskof galling particularly in case of cage guided valves. Vendor shall select propermaterial pairs, surface fmish, hardness and clearances wherever possibility ofgalling exist.

Under extreme temperature conditions, vendor shall consider increased clearancesat room temperature and seal welding of threaded seat rings etc. Hard facing oftrim shall be used in high temperatures. For very low temperature application,material used shall have adequate cold impact strength.

For globe/angle/3-way type of control valves, stem and plug shall be detachable andshall be attached together by suitable threaded design secured with a pin to avoidplug rotation during operation.

Copyright EIL All rights reservedFormat No. 8-00-0001-F1 Rev. 0Page 2638 of 3574


6-52-0031 Rev. 3Page 12 of 20

FOR CONTROL VALVESzlel ENGINEERS STANDARD SPECIFICATION

Ogeji 015jeg INDIA LIMITEDIA Govt of India Undertaking)

For top and bottom guided control valves with sizes above 8", post and guidebushing design shall be used to prevent rotation of plug and stem.

Whenever cavitation conditions are expected, vendor shall select a special anti-cavitation trim design and shall use trim material of sufficiently high hardness.

g) Whenever the possibility of aerodynamic noise in a control valve exists under anyoperating condition specified in purchaser's data sheet, vendor shall select a speciallow noise trim for that application.

2.2.3.2 The plug inherent characteristics shall be as indicated in the purchaser's data sheet.However, following shall be followed unless otherwise specified:

Control valves with low noise and anti-cavitation trim design shall have modifiedequal percentage or linear characteristics.

Rotary type control valves shall have modified equal percentage or equalpercentage characteristics.

Control valves with flow co-efficient less than 0.4 shall have equal percentage orlinear characteristics.

All other control valves shall have equal percentage characteristics.

Whenever linear or modified equal percentage characteristics are specified, equal percentagecharacteristics shall also be acceptable. Characterized positioner cam design to meetspecified inherent control valve characteristics shall not be offered.

2.2.3.3 Trim Material

2.2.3.3.1 Whenever stellited trim is specified in the data sheets following material of construction forthe trim parts shall be acceptable.

Plug and seat Stellite sheathing/hard alloy coating or solid stellite

Cage Nitrided or stellite sheathing/hard alloy coating or solidstellite.

Guide bushing Stellite coating/sheathing or solid stellite

Valve stem Hardened SS /Inconel X-760

Special material requirements, if specified in the datasheets, shall supercede the abovementioned requirements.

2.2.3.3.2 Whenever hardened SS trim is specified in the purchaser's data sheet, following material ofconstruction for the trim parts shall be acceptable provided same are compatible with thespecified process conditions;

Plug and seat Stellite sheath/hard alloy coating or 17-4PH SS or 440C

Cage Nitrided or stellite sheathing/coating, solid stellite, ENCcoating, 17-4 PH SS

Guide bushing 440C, 316SS stellited, 17-4 PH SS or solid stellite

Valve stem 17-4 PH SS



6-52-0031 Rev. 3Page 13 of 20 Wren rrecnyeasi,NcirA)

1i11Mell ENGINEERS STANDARD SPECIFICATION

$'gar faf5reg INDIA LIMITED FOR CONTROL VALVESIA Gov, of India Undertakmg)

2.2.3.3.3 Minimum acceptable hardness in case of stellited or hardened trim shall be of the order ofRC 38 (BHN 352) to RC 45 (BHN 429).

2.2.3.4 Leakage class

Leakage class as per ANSI FCI 70.2 shall be specified in the purchaser's data sheetfor each control valve. Where no leakage class is specified, the same shall beconsidered as Class IV. Higher leakage class shall be provided wherever indicated inpurchaser's data sheet.

For control valves specified with Class VI leakage class, vendor shall select the softseat (elastomer) material suitable for the process conditions i.e., shut off pressure,maximum temperature and process fluid.

2.2.3.5 Control valve experiencing cavitation, flashing and noise are generally identified in thepurchaser's data sheet. In case vendor's calculation show occurrence of cavitation, flashingor noise under any of the specified process condition, vendor shall select proper type ofvalve trim to suit such process conditions.

2.3 Sizing

2.3.1 The control valve capacities in terms of flow coefficient (Cv) shown in the purchaser's datasheets have been calculated based on the formulae given in the standard ISA 75.01 "Controlvalve sizing equations".

All factors used while arriving at the sizing are also as per ISA 75.01. Vendor must resizethe control valves considering various factors specific to the offered valves.

2.3.2 Purchaser's data sheet indicates calculated flow co-efficient values at minimum, normal andmaximum operating conditions. Vendor shall calculate this co-efficient as per the offeredcontrol valve and select the size considering valve openings as under:

At maximum flow - less than 90% open

At normal flow - typically 75% open

At minimum flow - more than 10% open

2.3.3 Rangeability of globe type of valves shall be 30:1, as a minimum. Vendor shall ensure thatthe actual rangeability of offered valves shall meet these requirements. For other types ofoffered control valves, vendor to specify that the available rangeability of the offered valvesmeet the requirements specified in the purchaser's data sheets.

2.3.4. Conventional Butterfly valves shall be sized assuming a 60 opening at maximum flow.Wherever high performance butterfly valves are specified, these shall be sized consideringmaximum opening of 90 at maximum flow.

2.4 Noise

2.4.1 Vendor shall examine each control valve for noise generation possibilities. The noise levelshall be calculated as per ISA 75.17 or any other equivalent standard.

2.4.2 Noise generated by control valve during operation shall be limited to OSHA specified levelsi.e. the maximum allowable noise shall be less than 85 dBA, when measured at a distancegoverned by ISA 75.17.


darat.iexfat5legRnETteirotedg ani.) (A Govt of India Undedalong)

ENGINEERSSTANDARD SPECIFICATIONINDIA LIMITED FOR CONTROL VALVES


6-52-0031 Rev. 3Page 14 of 20

2.4.3 If the predicted noise level is found to exceed 85 dBA SPL, control valve shall be treated fornoise. Source treatment for noise shall be resorted to. When source treatment for noise is notsufficient to reduce the noise level below 85 dBA, vendor shall provide path treatment likediffuser plate/silencer etc in addition to source treatment so as to reduce the level below85dBA. Whenever additional path treatment is recommended, the maximum differentialpressure across the silencer/diffuser plate shall not exceed 40% of the specified differentialpressure.

2.4.4 Vendor shall also furnish noise calculations with and without the use of these devices andthe noise abatement achieved in individual components.

2.4.5 Diffuser plate shall be inserted between control valve body and pipe flanges. Vendor shallsupply long studs and nuts along with a pair of gaskets on the downstream side with materialas per Annexure-1 and Annexure-2 attached with this specification.

In cases where the diffuser plate size is higher than the valve body size or there is a need ofmultiple diffuser plates, vendor shall supply the complete diffuser assembly with flangedend connections.

2.4.6 The silencer whenever offered for noise abatement shall always be supplied with flangedend connections.

2.5Packing Box, Bonnet and Stem

2.5.1 Packing Box

2.5.1.1 The packing box shall be flanged bolted to the bonnet and shall meet the requirementsspecified in purchaser's data sheet.

2.5.1.2 Generally low friction type packing like braided teflon will be used wherever operatingconditions permit. For high temperature application (>200C), Grafoil or equivalent gasketsuitable for the specified service shall be selected. Asbestos based packing material shall notbe used.

2.5.1.3 Where specifically indicated, control valve shall have its packing box drilled and tapped to1/4" NPT (F) for connecting external lubricator. When external lubricator is not provided,this hole shall be plugged.

2.5.1.4 An isolating valve shall be provided with all valves having external lubrication provision.Vendor shall specify the lubricator stick material used in each case.

2.5.1.5 For application in vacuum service, vendor to provide inverted packing design suitable forvacuum service. For pressure-cum-vacuum service, the control valve shall have dualpacking design suitable for the application. Dual packing design shall also be provided forcontrol valves in toxic service.

2.5.1.6 Wherever environmental packing design is specified vendor shall supply special packingdesign suitable to minimize fugitive emission.

2.5.2 Bonnet

2.5.2.1 The bonnet shall be flanged bolted to the body. Threaded bonnets are not permitted.

2.5.2.2 Wherever the operating temperature of the fluid is above 200C, extension or radiationfinned bonnet shall be provided. Vendor standard bonnet design shall also be acceptable ifthese are suitable for higher temperatures.


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ei$1g-ar faf5teu

Own twente11513,10.1) (A GEM of Ind. Undertaking)If ENGINEERS STANDARD SPECIFICATION

INDIA LIMITED FOR CONTROL VALVESSTANDARD SPECIFICATION No.

6-52-0031 Rev. 3Page 15 of 20

2.5.2.3 For temperature below 0C, vendor shall provide extended bonnet design. For valves incryogenic application bonnet extension shall be as per BS-6364 as a minimum

2.5.3 Stem

2.5.3.1 The stem surface finish shall be fine. Extra fine surface finish shall be provided whereverthe packing material is PTFE.

2.5.3.2 The stem/shaft shall be designed for the maximum thrust of the actuator without anymeasurable deflection.

2.5.3.3 The valve stem/shaft shall be connected to the actuator stem/shaft by suitable arrangement toavoid backlash problem.

2.6 Actuator

2.6.1 Pneumatic Actuator

2.6.1.1 Actuator shall be sized for the shut-off differential pressure indicated in purchaser's datasheets. However, for 3-way type control valve, the actuator shall be sized for maximumdifferential pressure, unless specifically indicated otherwise.

2.6.1.2 The actuator shall be designed to move the valve to the failure position specified in thepurchaser's data sheet. For failure position specified as 'fail-locked', vendor shall providefail-lock relays to meet the requirement.

2.6.1.3 Actuator casing shall be made of pressed steel or anodised aluminium. Non-metallicactuator casings shall not be offered.

2.6.1.4 Springs shall be corrosion-resistant and shall be cadmium or nickel-plated. Alternatelyvendor standard coating shall also be acceptable. These shall be of the enclosed type. Thecompression of the springs shall be adjustable.

2.6.1.5 In general, an actuator operating range of 0.2-to 1.0 kg/cm2g is preferred. However whenvendor standard actuator model is not able to meet the specified shutoff pressure, higheractuator operating range may be offered.

2.6.1.6 In general, spring opposed diaphragms type actuators shall be used. Only when this type ofactuator becomes extremely unwieldy, based on the data specified in the purchaser'sdatasheet, should a piston and cylinder type of actuator be considered.

2.6.1.7 Whenever piston and cylinder actuator is considered, single acting spring return type shall beused.

2.6.1.8 Whenever double acting springless type of actuator is unavoidable, all accessories like pilotvalves, booster relays, non-return valve, pressure gauge, volume tank etc. shall be providedto ensure desired action on air failure. The volume tank shall be sized considering fullstroking of the valve for two complete cycles. The volume tank shall be of carbon steelconstruction and sized as per ASME Section VIII with design pressure of 10kg/cm 2 g as aminimum. Accessories like pressure relief valves and tubing shall be of 316 Stainless steelconstruction. Other accessories can be of Cast Aluminium.

2.6.1.9 The actuator casings and diaphragms shall be designed for minimum twice the maximumpneumatic operating pressure of the control valve.

2.6.1.10 Valve stem position indicator shall be provided for every control valve. The positionindicator scale shall be marked from 0 to 100% in steps of 10%.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL All rights reservedPage 2642 of 3574

11M I ENGINEERS STANDARD SPECIFICATION

tairdg INDIAIndiaLIMITED FOR CONTROL VALVES

WWI eleaweastaciarn) IA of Und.tak..9)

(=)STANDARD SPECIFICATION No.

6-52-0031 Rev. 3Page 16 of 20

2.6.1.11 In general, side-mounted handwheels will be used. Hand wheels shall provide manualcontrol in both opening and closing directions independent of spring action. Hand-wheelsshall be of non-rising type suitable for accurate valve positioning .The hand-wheel actuatorshall be sized to provide the required thrust for valve positioning with 178N force appliedto the hand-wheel.

2.6.1.12 Actuator orientation shall be as per purchaser's requirements, in general. When, norequirements are indicated by purchaser, vendor shall provide recommended actuatororientation. It shall be possible to change this orientation at site for the offered valve-actuator combination in case it is found necessary.

2.6.2 Actuator Sizing

2.6.2.1 Vendor shall be fully responsible for the sizing and selection of the correct actuator for thespecified control valve. While sizing the actuator, vendor shall ensure that the actuator isable to develop sufficient thrust to properly seat the control valve plug/disc at the actuator airpressure (lowest specified pressure) and shut-off conditions specified in the purchaser's datasheets.

2.6.2.2 While sizing the actuator, vendor must ensure that the sizing factor indicated below are fullycomplied. Higher sizing factor may be considered if found necessary by vendor.

For control valves with leakage class IV and below, the actuator shall be sizedconsidering actuator thrust more than 1.3 times the total force induced by shut-offconditions specified in the data sheet and the force required to overcome packingfriction. Vendor shall utilize this factor as 1.5 in case the control valve is operatingbetween 80% to 90% or 10% to 20% in any of the specified conditions.

For control valves with leakage class V and above, the actuator shall be sizedconsidering actual thrust more than 1 7 times the total force induced by specifiedshut-off conditions in the purchaser's data sheet and the force required to overcomepacking friction.

2.7 Accessories

2.7.1 Positioners

2.7.1.1 Positioners shall be of force-balance type or smart digital type or field bus type as specifiedin the purchaser's datasheet. They shall be direct acting, with an adjustable gain unlessotherwise specified.

2.7.1.2 The pneumatic positioner shall be provided with an integral by-pass switch whenever theoperating range of the actuator is the same as that of the control signal.

2.7.1.3 Every positioner shall have two pressure gauges mounted on it, one each for air supply andfor positioner output to actuator. In addition , pneumatic positioner shall have third pressuregauge for control signal.

2.7.1.4 Pneumatic connections shall be 1/4" NPT (F) and cable entry shall be 'A" NPTF . Ifconnection for cable entry is different than that specified, suitable adapters shall be provided.

2.7.1.5 Positioners shall be side-mounted on the control valve and shall have corrosion resistantlinkages and rugged brackets.

2.7.2 Smart type and field bus type positioners


Page 2643 of 3574

eir 7IIFo1Llr.9

IO271 21MIU 051,7CRITA)

ENGINEERS STANDARD SPECIFICATIONINDIA LIMITED

FOR CONTROL VALVES(A Govt of India Undertaking)


6-52-0031 Rev. 3Page 17 of 20

Digital smart positioners or field bus type of positioners with diagnostic capabilities shall besupplied whenever specified in the purchaser's data sheets. These shall meet the followingminimum requirements:

The positioner sensor and sensing mechanism shall be rugged and shall not beaffected by the line/valve vibration. The performance of the positioners shall beimmune to above vibration.

The positioner's output and input range shall be field adjustable without anyhardware modification. The output from the positioners shall be available for bothsingle acting as well as double acting actuator.

Each positioner shall be operable, configurable and accessible through HARTcompatible hand held configurator/field bus configurator as applicable.

Unless otherwise specified, vendor shall offer smart positioner for control valves incritical applications such as split range, high pressure drop (>50kg/cm 2) hightemperature (>250C), low temperature (

611faq.At4Ogeil fafiteu

ENGINEERS STANDARD SPECIFICATIONINDIA LIMITED FOR CONTROL VALVESIA Govt of Inda Undertaking)


6-52-0031 Rev. 3Page 18 of 20

-Process Description/service

viii) Positioners shall be capable of supporting incremental DeviceDescription(DD) for extra functionality and/or software revisions in Devicememory.

h) The positioners shall be suitable to operate with commercially available assetmanagement softwares and shall support the following features, as a minimum:

It shall allow multimaster for configuration, calibration, diagnosis andmaintenance. The primary could be a host computer and secondary couldbe a hand held communicator.

It shall be ,capable of implementing universal commands. It shall bepossible to communicate all commands of commercially available assetmanagement system to/ from smart positioner.

i) The offered positioners shall meet the following performance characteristics: -

Overall control accuracy shall be better that 0.5% of span.

Repeatability shall be less than 0.25% of span.

Hysteresis shall be less than 0.5% of span.

Vendor shall supply the valve's operating signatures in the form of hardcopy and soft copy for each control valve supplied with smart positioners.The necessary software for advanced control valve diagnostics like seatring condition, gland packing condition, actuator leakage etc. shall also beincluded.

All positioners shall have metallic casing and cover either of stainless steel or ofanodized aluminium.

Fieldbus positioners shall support EDDL requirements as per IEC61 804/FDT/DTM requirements, as specified in job specifications..

2.7.3 Electro-Pneumatic Converter

2.7.3.1 Electro-pneumatic converter shall be of electronic feedback type unless specified otherwiseand shall be yoke mounted.

2.7.3.2 It shall have an integral terminal housing. Electro pneumatic converter with flying leadsshall not be acceptable.

2.7.3.3 Unless otherwise mentioned, it shall be intrinsically safe.

2.7.3.4 Pneumatic connections shall be 1/4" NPT (F). The electrical connections shall be 1/2" NPT(F). If they are different, suitable adapters shall be provided.

2.7.3.5 The overall accuracy of the electro-pneumatic converter shall be better than 0.3%.

2.7.4 Air Filter Regulator

2.7.4.1 Vendor shall supply air filter regulator with each positioner complete with an integral outputgauge.


Page 2645 of 3574

ENGINEERS STANDARD SPECIFICATIONINDIA LIMITED FOR CONTROL VALVESIA Govt of India Undenaktng)


$'g-ar faf5tu010757 011340.1)

6-52-0031 Rev. 3Page 19 of 20

2.7.4.2 Air filter regulator shall be sized considering the air supply pressure and flow required tomeet requirements specified in the purchaser's data sheets.

2.7.4.3 Filter material shall be sintered bronze. Filter size shall be maximum 5 microns. However,lower filter mesh size shall be considered to suit the electro pneumatic converter vendor'srequirement.

2.7.5 Valve Jacketing

2.7.5.1 The jacketed valves shall have steam inlet/outlet connections as flanged.

2.7.5.2 The valve end connections shall be one size higher than the normal valve connections forjacketed valve.

2.7.6 Hand held configurator for Smart Instruments

Hand Held configurator shall be universal type and shall be able to communicate with allmake and models of smart instruments with HART output like transmitters, smartpositioners etc., and shall be capable of carrying out all engineering functions likecalibration, configuration and diagnostics. The hand held configurator shall be certifiedintrinsically safe when used in hazardous area. Carrying case shall be supplied with eachconfigurator.

2.7.7 Field bus configuration :

The field bus configuration, whenever specified in datasheet, shall be provided withhardware and software for configuration and maintenance of field bus devices and also toperform diagnostics and troubleshooting of the field bus segments.

2.7.8 Battery charger

Both field bus and HART configurations shall be supplied with battery charger for batterycharging. Unless otherwise specified, battery charger shall operate at 220V 50Hz supply.

2.8 Special Service Valves

All control valves in oxygen and chlorine service shall be thoroughly degreased usingreagents like trichloro-ethylene or carbon tetra-chloride. End connections shall be blinded /plugged after this degreasing process in order to avoid entrance of grease and oil particles.

2.9 Finish

2.9.1 The body shall be painted as below:

Carbon steel body Light grey

Alloy steel body

-

Canary yellow

Stainless steel body

-

Natural

Above 150C - Aluminium paint (white colour)

Items like silencers, diffuser plate assemblies etc., shall be painted as per respective controlvalve body requirements.

2.9.2 The actuator shall be painted as below:

Direct action (open on air failure) valves

-

GreenFormat No. 8-00-0001-F1 Rev. 0

Copyright EIL All rights reservedPage 2646 of 3574


6-52-0031 Rev. 3Page 20 of 20

el ENGINEERS STANDARD SPECIFICATION

51gTIT 015reg INDIA LIMITED FOR CONTROL VALVES(tF2C1R 1111 JQl11A)IA Govt of lode Undeftak.o9)

Reverse acting (close on air failure) valve - Yellow

Actuator for shutdown valves Red

Items like air volume tanks etc., supplied as an accessory along with the actuators, shall bepainted as per corresponding actuator.

3.0NAMEPLATE

Each control valve shall have a stainless steel nameplate attached firmly to it at a visibleplace, furnishing the following information:

Tag number as per purchaser's data sheet.

Body and port sizes in inches.

Valve flow coefficient (Cv).

Stem travel in millimetres.

Action on air failure.

Spring range.

Air supply pressure.

Manufacturer's model number for the valve body, actuator and positioned.

4.0INSPECTION AND TESTING

Purchaser reserves the right to inspect and witness testing at vendor's works as perInspection Test Plan and approved quality documents. All these tests shall be completed bythe vendor and test reports shall be submitted to purchaser for scrutiny.

5.0SHIPPING

5.1The control valve and its accessories shall be supplied pre-assembled and pre-tubed.

5.2 All threaded and flanged openings shall be suitably protected to prevent entry of foreignmaterial.

5.3 Valves with external lubricators shall be lubricated prior to shipment.

5.4 Valves in oxygen and chlorine service shall be packed separately along with a certificateindicating 'CERTIFIED FOR OXYGEN / CHLORINE SERVICE', as applicable.

6.0REJECTION

6.1Vendor shall prepare their offer strictly as per clause 1.2 of this specification and shallattach only those documents and information, which are specifically indicated in thematerial requisition.

6.2 Any offer not conforming to above requirements, shall be summarily rejected.


Annexure 1 toSTANDARD SPECIFICATION NO.

6-52-0031 Rev. 3Page 1 of 1

STUD-BOLTS AND NUTSMATERIAL REQUIREMENT

lot ei ENGINEERSfgelf taMeg INDIA LIMITED

IA Govt of India Undertaking)

Sr. No. Piping Classes Nut and Bolt Material

1 A IA, A2A, A5A, A6A, A7A, A8A, A9A,A10A, Al 1A, A13A, A14A, A15A,A19A, A20A, A32A, A33A, A1K, A6K,AIM, A1N, B IA, B2A, B5A, B6A, B9A,B13A, B18A, B19A, B32A, BIK, B6K,BI8K, B1M, B3M, B5M, BIN, B6N,D1A, D2A, D5A, D18A, D1K, D18K,D18P, E1A, E2A, E5A, E5E, F5A

A-193 Gr. B7A-194 Gr. 2H

2 A16A, B16A A-193 Gr. B7MA-194 Gr. 2HM

3 A 1B, AID, A4F, A4G, BIB, B1D, B5D,B1E, B3F, B4F, B4G, D1B, D2B, DID,D2D, D5D, D5E, F2D

AI-193 Gr. B16A-194 GR. 4

4 A2K, B2K, D2K A-320 Gr. B8 CL.2A-194 Gr. 8

5 A4A, A 1H, B4A, B IH, D4A, D1H A-320 Gr. L7A-194 Gr. 4

6 A3Y A-307 Gr. BA-563 Gr. B

7 A3A, A3K, A3Y, A4Y, J3A A-307 Gr. BA-563 Gr. B

8 A IZ, A4Z, A5Y, A5Z, J2A,