SPECIFICATIONS FOR DOUBLE BLOCK & BLEED, AND · PDF fileSPECIFICATIONS FOR DOUBLE BLOCK & BLEED, ... of Double block & bleed and double isolation valves shall be in ... BS-EN 1515-1

DOUBLE BLOCK & BLEED AND DOUBLE ISOLATION VALVES

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SPECIFICATIONS FOR

DOUBLE BLOCK & BLEED,

AND

DOUBLE ISOLATION VALVES

Issue and Revision Record:

Revision Date BPCL HPCL IOCL Description

0 23.03.2011 Issued for Tendering


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INDEX

A) TECHNICAL SPECIFICATIONS : DOUBLE BLOCK & BLEED AND DOUBLE ISOLATION VALVES

1.0 SCOPE

2.0 APPLICABLE CODES, SPECIFICATIONS & STANDARDS

3.0 GENERAL FEATURES / SPECIFICATIONS

4.0 DESIGN DETAILS

5.0 QUALITY CONTROL / INSPECTION & TESTING

6.0 DOCUMENTATION

7.0 MARKING

8.0 PAINTING / PREPARATION FOR SHIPMENT

9.0 SPARES & SPECIAL TOOLS

10.0 COMMISSIONING ASSISTANCE & WARRANTIES

11.0 TRAINING


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B) TECHNICAL SPECIFICATIONS : FLAME PROOF ACTUATORS

1.0 SCOPE

2.0 CODES & STANDARDS

3.0 GENERAL REQUIREMENTS

4.0 TECHNICAL SPECIFICATIONS

5.0 REQUIREMENTS OF HAZARDOUS AREAS

6.0 INSPECTION , TESTING AND ACCEPTANCE

7.0 PACKING AND DISPATCH

8.0 SPARES & SPECIAL TOOLS

9.0 COMMISSIONING ASSISTANCE

10.0 WARRANTIES

11.0 DATA SHEET FOR MOV ACTUATORS- PURCHASOR’S DATA

12.0 DATA SHEET FOR MOV ACTUATORS- MANUFACTURERES’S’S DATA ANNEXURE –A : QUALITY ASSURANCE PLANS


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A) TECHNICAL SPECIFICATIONS : DOUBLE BLOCK & BLEED AND DOUBLE ISOLATION VALVES

1.0 SCOPE :

This specification establishes the technical requirements for Double block & bleed and double Isolation valves with single operator to be used for positive isolation purpose for replacement of existing hammer blind valves in Oil Installations, handling refined petroleum liquid hydrocarbon products ( MS,SKO,HSD,NAPHTHA/ATF/ Ethanol blended Gasoline (up to 10%) etc.

The Size and pressure rating of valves required shall be as per BOQ (Bill of quantities) of the tender document. The valve shall be conforming to API-6D specifications & shall bear API-6D monogram.

This specification covers the minimum requirements for the design, manufacture, Assembly, Inspection, testing, certification & delivery of Manual / electrically operated Double block & bleed and double Isolation valves complete with all accessories. Specifications of electrical actuators is covered in section B of this document.

2.0 Applicable Codes, Specifications and Standards: 2.1 Applicable Codes & standards

2.1.1 The design, manufacture, assembly, inspection, testing and certification of Double block & bleed and double isolation valves shall be in accordance with the latest edition of the codes & standards including amendments as mentioned in the tender specifications. Some of the standards have been listed below for ready reference :

API-6D Specifications of Pipeline valves

API-6FA Specification for Fire test for Valves.

API-598 Valve Inspection and Testing

ASME B1.20.1 Pipe Threads, General Purpose (inch)

ASME B16.5 Steel Pipe Flanges and Flanged Fittings

ASME B16.10 Face-to-Face and End-to-End Dimensions of Valves ASME B16.34 Valves – Flanged, Threaded, and Welding End


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ASME B31.3 Chemical Plant and Petroleum Refinery Piping

ASME B31.4

2004 Liquid transportation systems for hydrocarbons and other liquids

ANSI B46.1 Surface Texture (Surface Roughness, Waviness & Lay)

BS EN 12266 Industrial Valves, Testing of valves, test procedures & acceptance criteria.

BS-EN 102222

Specification for steel forgings for pressure purposes

BS-EN 10213 Specification for steel castings for pressure purposes.

BS 1560 Steel pipe flanges and flanged fittings.

BS-EN 1092 Flanges and their Joints-Circular flanges for pipes, valves, fittings and accessories, PN designated.

BS-EN 1515-1 Flanges and their Joints.

BS 5146 Inspection and test of steel valves for the petroleum, petrochemical & allied Industries

MSS-SP-6 Standard finishes for contact faces of pipe flanges and connecting end flanges of valves and fittings

MSS-SP-25 Standard marking system for valves, fittings, flanges and unions.

MSS-SP-44 Steel pipeline flanges.

MSS-SP-45 By-pass and drain connection standard

MSS-SP-61 Pressure Testing of Steel Valves

MSS-SP 55 Quality standard for steel castings-visual method.

MSS-SP 61 Hydrostatic testing of steel-valves.

2.2 Deviations to specifications :

2.2.1 The Bidder shall provide an itemized list of any deviations to this specification.These shall be listed on the Compliance sheet with seal & duly signed by authorized signatory & shall be submitted along with offer by the Bidder.

2.2.2 Where a conflict between standards occurs then the Bidder shall seek a clarification

ruling from the Owner. Where a deviation from the standard is required, then the


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Bidder shall make a formal request with full supporting information.

2.2.3 Only those deviations that are agreed between the Owner and the Bidder will be Incorporated into the requisition at the time of order.

2.3 Conflicting Requirements :

In case of conflict between the requirements of this specification, API 6-D and the Codes, Standards and Specifications referred in clause 2.1 above, the requirements of this specification shall govern. Order of precedence shall be as follows: First priority - This Specification Second priority - API 6-D/6FA Third priority - Other Referred Codes & Standards Fourth priority - Manufacturer‟s Standard Note: Should any conflict arise either before or after order placement the Bidder shall immediately inform the Owner for technical resolution of the conflict.

2.4 Abbreviations & Terminology :

CE Carbon Equivalent

FAT Factory Acceptance Test

BPCL Bharat Petroleum Corporation Ltd.

IOCL Indian Oil Corporation Ltd.

HPCL Hindustan Petroleum Corporation Ltd.

POL Petroleum, Oil Installations of Oil Companies

MOV Motor operated valve

HOV Hand operated valve

QAP Quality Assurance plan


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2.5 White Oil Product Details : In the table below, Product Characteristics of the products in POL terminal are mentioned as general guidelines to bidders

PRODUCT CHARACTERISTICS

Product Flash

Point

(⁰ C)

Specific

Gravity

(gm/cc)

Vapor

pressure

(kg/cm²a)

Viscosity

(cST)

Pumping

Temp.(⁰C)

HSD – High

Speed Diesel

> 35 0.82 – 0.86 < 0.4 2-5 @

40⁰ C

Ambient

MS – Motor

Spirit

(-) 30 0.73 0.7 < 0.7 Ambient

Naptha (-) 20 0.69-0.78 < 0.7 < 0.7 Ambient

ATF – Aviation

Turbine Fuel

> 38 0.8 < 0.4 2.56 Ambient

SKO – Super

Kerosene Oil

> 35 0.8 < 0.05 1.97 Ambient

MTO- Mineral

Turpentine Oil

33 0.82 0.01 14.92 Ambient

Hexane (-)23.3 0.66 0.37 0.277 Ambient

Ethanol 16.6 0.79 0.08 1.2 Ambient

3.0 GENERAL FEATURES / SPECIFICATIONS:

3.1 The valve shall have one operator only. Gear operation (with or without reduction gear) shall be provided as per manufacturer‟s specifications / relevant standards.

3.2 Gear operator shall be provided with position indicators for open/ close

positions, with limit stops as per manufacturer‟s design in line with API-6D. The operators shall be totally enclosed of helical worm/bevel or combination of helical worm, bevel and spur gear in grease case with grease nipples/ plugs or as per specifications of manufacturers with weather protection.

3.3 Gear operator shall be so designed to operate the valve at break away

torque as defined in API-6D. The maximum force required at the hand-wheel or wrench to apply the breakaway torque or thrust shall not exceed 360 N (80 lbf). However failing to meet the above requirements vendor shall offer gear-operated valve and quote as above.


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3.4 Valves with wrench or lever operators shall have “open” position Indicators with limit stops.

3.5 Wrenches for valves, if required, shall either be of an integral design or

consist of a head which fits on the stem and is designed to take an extended handle. The head design shall allow permanent attachment of the extended section if specified by the purchaser. Wrenches that are of integral design (not loose) shall not be longer than twice the face-to-face or end-to-end dimension unless otherwise agreed. Hand-wheel diameter(s) shall not exceed the face-to-face or end-to-end length of the valve or 1000 mm, whichever is smaller, unless otherwise agreed. Except for valve sizes DN 40 (NPS 1.) and smaller, spokes shall not extend beyond the perimeter of the hand-wheel unless otherwise agreed. If specified by the purchaser, the hand-wheel of the gearbox input shaft shall be provided with a torque-limiting device, such as a shear pin, to prevent damage to the drive train. Direction of closing shall be clockwise, unless otherwise specified.

3.6 Vendor shall be supplying flame proof / PESO,India approved electrical

actuators along with the valves where ever specified in the BOQ. Actuators of ROTORK, LIMTORQUE, AUMA makes shall be acceptable. Other makes may be accepted who have proven performance worldwide since previous 3 years from date of NIT & have well equipped maintenance & service support in India as on the date of NIT. Valve vendors to submit full details to verify their full credentials including performance certificate from 3 major users in the oil industry.

3.7 The valves shall be Expanding gate valves with rising stem having

two piece parallel expanding gates with resilient seats or twin seal plug valves having two independent resilient Retractable seats. The valve shall be designed to provide a tight mechanical seal and positive shut-off under high and low differential Pressures.

3.8 Rotation of the hand wheel/operator while opening shall lift / rotate the

plug or gate without wiping the seals due to retracting action of the sealing slips so that during rotation / lifting of the plug / gate, clearance is maintained between the sealing slips and the valve body to minimize wear & tear of the seals. Rotation of the hand wheel/operator while closing shall lower the plug or gate after the sealing slips are aligned with the valve body and force the sealing slips against the valve body for positive closure independent of line operating pressure.


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3.9 Motor operated valves shall be directly mounted with flame proof electric actuators / gear operators and delivered to the field as a complete unit.

3.10 RELIEF SYSTEM: The valves are to be provided with integral thermal relief

system consisting of suitable valves & piping as per ratings of the valves to relieve the pressure build up in the internal body cavity when the valve is closed. Relief valves shall open at minimum 25 psi differential pressure or as specified by the manufacturer within limits as specified under clause 7.8 of API-6D and shall discharge to the upstream side of the valve. Thermal relief valves shall be externally placed in a way so that the same can be serviced without dismantling the main valve.

3.11 BLEED VALVES: Manually operated bleed valves are to be provided on

the valve that can be opened to verify that the valves are not leaking when in the closed position. Suitable discharge piping with isolation valves and end plug / suitable adaptor for extension purpose, shall be provided so that the released liquid from each bleed valve can be contained locally. There shall be a provision to provide necessary instruments for remote checking of valve integrity in control room, if required by the user company.

3.12 Vendor shall quote in strict accordance with the valves data/ specification

sheets, subject technical notes and all other enclosures to the tender document. Any deviation to be highlighted clearly in the deviation sheets enclosed.

3.13 Vendor shall supply valves along with auxiliaries, if any, such as gear

operator, bypasses, drains etc. wherever specified in the specification sheets, subject notes and other enclosures to the tender document.

3.14 Valve body shall preferably have provision to drain any muck or dirt

remains inside the Valve body, which can damage the seats. 3.15 The valve bodies shall be suitable for above ground open atmosphere

Installation & shall be suitable for ambient Temperature range of -10ºC to + 55ºC & Relative humidity up to 100 %.

3.16 The valve shall be maintainable while being in position either by unbolting from Top or bottom or both. Valve design shall permit sealing slips to be replaced from the Top or bottom with the valve mounted in the piping. Vendor to mention the clearance required below the valve for on-line maintenance.


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4.0 DESIGN DETAILS : 4.1 Valve shall be designed, manufactured, tested, inspected as per API-

6D/ISO 14313, ASME B16.34 & other manufacturing standards, design codes and standards (latest editions) indicated in latest edition of API-6D . Each valve shall bear API-6D monogram.

4.2 Metallic Pressure-containing and pressure controlling parts, including

bolting, shall be designed with materials as per manufacturers‟ standards complying with minimum requirements as stipulated in clause 8 of API-6D.

All process-wetted parts, metallic and non-metallic, and lubricants shall be

suitable for the commissioning fluids and service specified by the purchaser. Metallic Materials shall be selected so as to avoid corrosion and galling, which would impair function and/or pressure containing capability. Selection of elastomeric materials for valves intended for hydrocarbon gas service at pressures of PN 100 (class 600) and above shall consider the effect of explosive decompression.

The wetted parts shall be suitable coated with chrome coating / plating,

Fluorocarbon coating & electro less nickel coating as required to enhance properties of materials for achieving longer life as per manufacturer‟s standards & Approved QAP.

Design and calculations for pressure-containing elements shall be in accordance with an internationally recognized design code or standard with consideration for pipe loads, operating forces, etc. The choice of standard shall be in line with API-6D. Pressure & temperature ratings for ASME class-rated valves shall be in accordance with the applicable rating table for the appropriate material group in ASME B16.34. Material of construction of critical components of valves has been tabulated in Annexure-I.

4.3 Face-to-Face and end-to-end dimensions of valves shall be in accordance

with Tables 2 to 6 of API-6D. Face-to-face and end-to-end dimensions for valve sizes not specified in Tables 2 to 6 shall be in accordance with ASME B16.10. Valve connections shall be ASME B16.5, Class 150 or Class 300, raised face flanged, as specified.

4.4 Positioning of cover must be provided to ensure correct Alignment of the

valve disc part or an arrangement of parts for securing a valve in the open and/or closed position. Locking devices shall be designed to lock the valve in the open and/or closed position. The position of the obturator shall not


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be altered by dynamic forces of the passing flow. Valves fitted with manual or powered actuators shall be furnished with a visible indicator to show the open and the closed position of the obturator.

4.5 For plug valves, the wrench and/or the position indicator shall be in line

with the pipeline when the valve is open and transverse when the valve is closed. The design shall be such that the component(s) of the indicator and/or wrench cannot be assembled to falsely indicate the valve position. Valves without position stops shall have provision for the verification of open and closed alignment with the operator/actuator removed.

4.6 Travel stops shall be provided on the valve and/or operator and they shall

locate the position of the obturator in the open and closed position. The travel stops shall not affect the sealing capability of the valve. Misalignment or improper assembly of components shall be prevented by suitable means, such as a dowel pin or fitting bolt, which ensures the correct location of manual or powered operators and stem extension assemblies.

4.7 The operating levers or handles on valves shall indicate, by their position,

whether the valve is open or closed. The open position shall be indicated when the lever or handle points in a direction parallel to the flow through the valve. In addition, it shall be impossible to reverse the indicating position inadvertently during reassembly of the valve. Suitable marking shall be done on the valve to indicate flow direction.

4.8 Welding, including repair welding of pressure-containing and pressure-

controlling parts shall be carried in line with clause 9 of API-6D. 4.9 Valve body/ bonnet shall be forged / cast as specified. Forgings are

acceptable in place of casting but not vice versa. For expanding gate valves, fabricated body ( using steel plates) is acceptable

4.10 Material of construction of yoke shall be minimum equivalent to body/

bonnet material. 4.11 Stem shall be forged or machined from forged/ rolled bar. No casting is

permitted. 4.12 Graphite material used for stem packing shall be chloride free i.e.

leachable chlorides shall be less than 50 PPM. 4.13 Stelliting/ hard-facing by deposition, if required shall be min.1.6mm or as

per manufacturer‟s specifications.


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4.14 Suitable gaskets are to be provided for body bonnet joints as per Manufacturer‟s specifications in line with the requirement of standards.

4.15 valves shall be supplied with antistatic arrangement as specified in API-

6D

4.16 The MOVs are to be installed in an open area and the actuators shall be IP-65. The testing of complete assemblies of MOVs along with the actuators shall be carried out by the supplier at his works.

4.17 Ends of flanged valve of 22” size shall match corresponding flanges to

MSS-SP44 unless otherwise specified.

4.18 For reduced bore valves, Minimum bore size shall be as per API-6D. Reduced-opening valves with a circular opening through the obturator shall be supplied with a minimum bore as follows, unless otherwise specified:

� valves DN 300 (NPS 12) and below: one size below nominal size of valve with bore according to Table 1 of API-6D; � Valves DN 350 (NPS 14) to DN 600 (NPS 24): two sizes below nominal size of valve with bore according to Table 1of API-6D; � Valves above DN 600 (NPS 24): by agreement / as per standards of manufacture.

Reduced-opening valves with a non-circular opening through the obturator shall be supplied as per API-6D .

4.19 The valve shall be maintainable on line, without having a need to remove

the valve body from the piping system. Valve seat shall be removable & replaceable without removing the valve from the manifold or pipe line. For gate valves, Valve gate, segment and seat rings shall be removable without removing the valve from the manifold or pipe line for ease of maintenance.

4.20 Gate/Plug design shall be such that it shall expand only in the closed

position and provide a tight mechanical seal. Increases or decreases in line pressure shall not affect the mechanical sealing.

4.21 The design of stem protector and position indicator must be rugged and

weatherproof. The position indicator shall be sealed at its exit point from the stem protector using a suitable mechanism. Operators, stem extensions and their interfaces shall be sealed to prevent ingress of external contaminants and moisture. Operators and stem extension


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assemblies shall be provided with a means of preventing pressure build-up in the mechanism resulting from stem or bonnet seal leakage.

4.22 Valve stem packing shall be designed for easy on-line maintenance. The

stem shall be of anti blowout design, permitting replacement of the stem seals with the valve in fully closed position. Valves shall be designed to ensure that the stem does not eject under any internal pressure condition or if the packing gland components and/or valve operator mounting components are removed. The stem integrity shall be ensured as per vendor‟s design.

4.23 Manufacturer of the valve shall ensure bonding of slip seals for

integrity & there shall be established procedures for ensuring QA/QC of the sealing materials & bonding. Viton material sourced from DUPONT / 3M shall only be accepted.

4.24 Drain, vent and sealant lines, if required as per design of the valve shall be

provided and shall be extended by means of rigid pipe work, if necessary. The lines shall be fastened to the valve and/ or extensions and terminate close to the stem extension top works, by agreement. Drain and vent lines shall :

� have a design pressure not less than the rated pressure of the valve on which they are installed; � be capable of withstanding the hydrostatic shell test pressure of the valve � be designed in accordance with a recognised design code; � be suitable for blow-down operation, where applicable.

Sealant lines for stem sealant injection, if required shall have a design pressure not less than the greater of the pipeline valve rated pressure and the injection pressure. If not specified by the purchaser, the manufacturer shall advise the maximum injection pressure for the system. The size of the sealant lines shall be by agreement. Prior to assembly, the internal bores of sealant lines shall be clean and free from rust and any foreign particles.

Drain and vent block valves shall be provided, if specified, shall have a rated pressure not less than the valve on which they are installed and be suitable for blow-down operation. Bypass, drain and vent connections and plug entries shall be drilled and threaded unless otherwise specified / as per manufacturing standards


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Thread profiles shall be tapered unless otherwise agreed. Tapered threads shall be capable of providing a seal and comply with ASME B1.20.1. If the use of parallel threads is specified, the connection shall have a head section for trapping and retaining a sealing member suitable for the specified valve service. Parallel threads shall comply with ISO 228-1. Minimum sizes shall be in accordance with Table 7 of API-6D.

4.25 The pressure as determined in accordance with clause 7.2 of API-6D shall be the maximum pressure differential (MPD) at which the valve is required to be opened by the lever, gearbox or actuator. The manufacturer shall provide the following data to the purchaser in technical bid:

� flow coefficient Cv or Kv; � breakaway thrust or torque for new valve; � maximum allowable stem thrust or torque on the valve and, if applicable, the maximum allowable input torque to the gearbox; � Number of turns for manually operated valves.

4.26 Drive trains: The design thrust or torque for all drive train calculations shall be at Least two times the breakaway thrust or torque to allow for thrust or torque increase in service due to infrequent cycling and the adverse effect of debris. Allowable Tensile stresses in drive train components, including stem extensions, shall not exceed 67 % of SMYS when delivering the design thrust or torque. Shear, torsion and bearing stresses shall not exceed the limits specified in ASME Code Section VIII, Division 2, Part AD-132, except that design stress intensity values, Sm, shall be 67 % of SMYS. These stress limits do not apply to the components of rolling-element or other proprietary bearings or high bearing strength capable materials that are included in the drive train where manufacturer's recommendations or limits derived from tests and service experience apply. These limits shall be justified in design documents, if requested.

The drive train shall be designed such that the weakest component is outside the Pressure boundary. A strength efficiency factor of 0,75 shall be used for fillet Welds .

Note — If an actuator or operator can deliver a thrust or torque that is greater than the design thrust or torque of the drive train, such a thrust or torque can result in permanent deformation or failure of drive train Components. Hence careful selection shall be carried out for actuator.


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Deflections of the extended drive train shall not prevent the obturator from reaching the fully closed or fully open position. For all valves, attention shall be paid to deflection and strain. Adherence to the allowable stress limits of Design codes alone might not result in a functionally acceptable design. The manufacturer shall demonstrate, by calculation or test, that under loads resulting from design pressure and any defined pipe or external loads, distortion of the obturator or seat does not impair functionality or sealing.

4.27 Valves of size DN 200 (NPS 8) and larger shall be provided with lifting points. The manufacturer shall verify suitability of the lifting points. The valve manufacturer shall verify the suitability of the lifting points for the complete valve and operator assembly.

4.28 Materials of construction for critical valve components shall be as given

below in table A & B TABLE –A (DBB PLUG VALVES)

S.NO. DESCRIPTION SPECIFICATION VENDORS CONFIRMATION

4 Body Cast Carbon Steel ASTM A 216 WCC /WCB

5 Bonnet / Lower plate

Cast Carbon Steel ASTM A516 Gr. 70 / ASTM A 216 WCC/WCB

6 Plug Cast Carbon Steel ASTM A 216 WCC/WCB, case hardened and 0.003 in. ENP

7 Stem AISI 4140 (1.5 mm steliting) / ASTM-A479 TY 410 (0.03in. ENP)

8 Slips Cast Ductile iron ASTM A 536-80-55-06/ A395 Gr. 60-40-18

9 Gasket Flexible Graphite.

10 Gland packing Flexible Graphite

11 Body Fire seals Graphite

12 Slip seals Viton (Dupont / 3M)

13 Bolts/Nuts ASTM A193 Gr.B7 /ASTM A 194 Gr2H

14 Tubing / connectors /needle valves

SS-316


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TABLE -B (DBB GATE VALVES)

S. No DESCRIPTION SPECIFICATION VENDORS CONFIRMATION

1 Body ASTM A 516 GR. 70 / ASTM A 216 GR. WCB/WCC

2 Bonnet ASTM A 516 GR. 70 /ASTM A 216 GR. WCB/WCC

3 Bolts/Nuts ASTM A193 Gr B7/ASTM A 194 Gr2H

4 STEM

AISI 4140 (1.5 mm stelliting / ENP)

6 STEM SEAL

GRAFOIL TYPE TO COMPLY WITH FIRE SAFE REQUIREMENT

7 GATE / SEGMENT

A216WCC/ WCB or ASTM A 516(ENP)

8 SEAT ASSEMBLY

ASTM A 516-GR.70 OR A105

9 Centralised arm

ASTM A 516-GR.70(ENP)

10 SEAT SEAL

VITON (DUPONT/3M)

11 O-RING SEALS

VITON GFLT

12 PRESSURE RELEASE VALVE

SS-316

13 Packing Graphite

14 End Flanges ASTM A 105,125AARH

15 Tubing / connectors /check /needle valves

SS-316

4.26 All applicable codes and standards for design, materials, manufacture, testing,

inspection etc. shall be of latest editions. Vendor to list all the specifications / standards applicable.


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5.0 QUALITY CONTROL / INSPECTION & TESTING 5.1 Valve shall be subject to all the tests and checks required as per quality

control requirements of clause 10.0 & testing requirements of clause 11.0 of API-6D & other relevant standards & as per the QAP specified in the tender document. However vendor shall submit their detailed QAP in line with the specifications stipulated in this tender document. NDE tests shall be carried out in line with Annexure-A of API-6D. Vendor shall be deploying services of TPIA for witnessing tests as per approved QAP at their (Vendor‟s) cost. Approved TPIA agencies are:

TUV,

Lloyds,

Certification Engineers India LTD,

Det Norske Veritas,

SGS.

5.2 Purchaser, at its discretion may depute their representatives at their own cost to witness critical tests at manufacturing works in addition to TPIA.

Chemical composition and mechanical properties shall be checked as per

relevant material standards and this specification, for each heat of steel used.

Non-destructive examination of individual valve material and components consisting of, but not limited to castings, forgings, plate and assembly welds shall be carried out by the Manufacturer in line with API-6D.

5.3 The manufacturer shall submit a certificate covering the testing of the valves and Certifying the materials of construction used in the valves, according to API 6D and other relevant standards of Latest edition.

5.4 Vendor shall submit type test certificates for fugitive emission tests carried out in accordance with TU-LUFT / ISO 15848 / US Clean air act or equivalent standards. 5.5 Valves shall be tested prior to shipment in line with the requirements of

API-6D and agreed QAP. Testing shall be performed in the sequence detailed in API-6D. Pressure testing shall be carried out before coating of the valves. Test fluid shall be fresh water or, by agreement, light-weight oil having a viscosity not exceeding that of water. Water used for testing shall contain a corrosion inhibitor.


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5.6 Valves shall be tested with the seating and sealing surfaces free from sealant except where the sealant is the primary means of sealing. A secondary sealant system, if provided, shall not be used before or during tests.

5.7 Supply pressure shall be stabilized prior to the start of pressure testing and

shall be held for the minimum test durations listed in Tables 9, 10 and 11 of API-6D.

5.8 Fire type-testing certification of the design shall be provided. The fire-

resistance design of valves shall be qualified by fire type-testing in accordance with ISO 10497.Fire resistance designs already qualified to ISO 10497, API 6FA, API 6FC, API 6FD or API 607 are also acceptable as per stipulations of API-6D.

5.9 Hydrostatic shell test: Valve ends shall be closed off and the obturator

placed in the partially open position during the test. If specified by the purchaser, the method of closing the ends shall permit the transmission of the full-pressure Force acting on the end blanks to the valve body. If present, external relief valves shall be removed and their connections plugged. The test pressure shall be 1,5 or more times the pressure rating determined in accordance with 7.2 for Material at 38 °C (100 °F). The duration shall not be less than that specified in Table 10. No visible leakage is permitted during the hydrostatic shell test.

After hydrostatic shell testing, external relief valves shall be fitted to the

valve. The connection to the valve body shall be tested at 95 % of the set pressure of the relief valve for 2 min for valve sizes up to and including DN 100 (NPS 4), and 5 min for valve sizes DN 150 (NPS 6) and larger. The relief-valve connection shall be free of visible leakage during this period. All the valves are required to be tested for hydrostatic shell test.

5.10 Hydrostatic seat test: The test pressure for all seat tests shall not be

less than 1.1 times the pressure rating determined in accordance with clause 7.2 of API-6D for material at 38 °C (100 °F). The test duration shall be in accordance with Table 11. The test procedures for various types of block valve shall be in line with para 11.4.4.of API-6D

Acceptance criteria: Leakage for soft-seated valves shall comply with the requirements of API 598. API-598 states for shell and backseat tests, no visible leakage is permitted. If the fluid is a liquid, there shall be no visible evidence of drops


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or wetting of the external surfaces (no visible leakage through the body, body liner, if any, and body-to-bonnet joint and no structural damage). If the test fluid is air or gas, no leakage shall be revealed by the established detection method. For both the low-pressure closure test and the high-pressure closure test, visual evidence of leakage through the disk, behind the seat rings, or past the shaft seals (of valves that have this feature) is not permitted (Plastic deformation of resilient seats and seals is not considered structural damage). The allowable rate for leakage of test fluid past the seats, for the duration of the tests, is listed in the following table:

Valve Size

All Resilient Seated Valves

All Metal-Seated Valves (except Check Valves)

Metal-Seated Check Valves

Liquid Test (drops/min)

Gas Test (bubbles/min)

Liquid Test (drops/min)

Gas Test (bubbles/min)

<= 2" 0 0 (b) 0 (b) (c) (d)

2.5" - 6"" 0 12 24 (c) (d)

8" - 12"" 0 20 40 (c) (d)

>= 14"" 0 28 56 (c) (d)

Where : (a) 1 milliliter is considered equivalent to 16 drops (b) There shall be no leakage for the minimum specified test duration. For liquid test, 0 drop means no visible leakage per minimum specified test duration. For gas test, 0 bubble means less then 1 bubble per minimum specified test duration. (c) The maximum permissible leakage rate shall be 0.18 cubic inch (3 cubic centimeters) per minute per inch of nominal pipe size. (d) The maximum permissible leakage rates shall be 1.5 standard cubic feet (0.042 cubic meter) of gas per hour per inch of nominal pipe size. All the valves are required to be tested for hydrostatic seat test.


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Additional seat testing: Since the valves are expected to have the functionality for the valve to be that of double-block-and-bleed (DBB) & double-isolation-and-bleed (DIB-1), the test described in Clause B.10 & B.11 of API-6D shall be performed . 10 % of the valves of all sizes & types are required to be tested for Additional seat testing.

5.11 Test of thermal relief valve: The external relief valve shall be set and

certified to relieve at the specified pressure either by the relief-valve supplier or the valve manufacturer for all the valves .

5.12 Testing of drain, vent and sealant injection lines, if provided: drain and vent Lines shall be subject to a hydrostatic test with all the valves. 5.13 Anti-static testing: The electrical resistance between the obturator and

the Valve body and between the stem/shaft and the valve body shall be measured using a direct-current power source not exceeding 12 V. The resistance shall be Measured on dry valves before pressure testing and shall not exceed 10 ohm 5 % of the valves of each size & type shall be tested for Anti-static testing.

5.14 Torque/thrust functional testing: The maximum torque or thrust required to Operate gate or plug valves shall be measured at the pressure

specified by the purchaser for critical valve operations. Thrust and torque testing shall be performed following hydrostatic shell testing and, if specified, prior to any low-pressure gas seat testing. The measured torque or thrust results shall be recorded and shall not exceed the manufacturer‟s documented breakaway torque/thrust. 1 % of the valves (min.1) of each size & type shall be tested.

5.15 Drive train strength test: The test torque shall be the greater of

a) Twice the manufacturer's predicted break-away torque/thrust, or b) Twice the measured break-away torque/thrust. The test torque shall be applied with obturator blocked for a minimum time of 1 min.

NOTE : For gate valves, the thrust can be tensile or compressive, whichever is the most stringent condition.


21

The test shall not cause any permanent visible deformation of the drive train. For plug valves, the total torsional deflection of the extended drive train when delivering the design torque shall not exceed the overlap contact angle between the seat and obturator. 1 % of the valves (min.1) of each size & type shall be tested for Drive train strength test.

. 6.0 DOCUMENTATION :

6.1 Vendor shall arrange to retain documents in his works as stipulated in API-6D.

6.2 In addition, Vendor shall arrange to submit following documents along with the consignment :

6.2.1 Detailed dimensioned, cross section drawing of each size of valve being

offered with parts/ material lists, weight etc. as manufacturer‟s / API / Other relevant applicable standard.

6.2.2 Drawings for valves with accessories like gear operator, extension bonnet, extended stems with stands bypass etc. giving major salient dimensions.

6.2.3 Material test certificates (physical property, chemical composition & heat

treatment report, radiography etc.) of the pressure containing parts & for the other parts shall also be furnished for verification during inspection.

6.2.4 Following supplementary documentation is required to be provided in line with API-6D as given below:

a) NDE records; b) Hardness test report on pressure-containing parts; c) Heat treatment certification records (e. g. charts); d) Pressure test / Leak test (Valve seat & Fugitive) & other test reports, (Including pressure, test Duration, test medium and Acceptance Criteria); e) coating/plating certification; f) Fire type-test certificates; g) Material inspection certificates in accordance with ISO 10474 or EN 10204, as applicable (the purchaser shall specify the type of Certification, and for which parts, when ordering);


22

h) Design verification by certification body/agency; i) Installation, operation and maintenance instructions/manuals;

6.2.5 All the documents as listed above shall be submitted in 3 copies Separately for each purchaser company (BPCL,IOCL & HPCL).

7 MARKING :

7.1 Valve markings, symbols, abbreviations etc. shall be in accordance with Table 12 of API-6D. Vendors name, valve rating, material designation, nominal size,direction of flow (if any) etc. as specified in the table 12 of API-6D shall be integral on the body.

7.2 Body/cover/closure stamping shall be performed using a low-stress die-stamp, rounded “V” or Dot Face type. Each valve shall be provided with an austenitic stainless steel nameplate securely affixed and so located that it is easily accessible. The marking on the nameplate shall be visually legible.

7.3 Each valve shall be marked with API-6D Monogram

8 PAINTING / PREPARATION FOR SHIPMENT :

8.1 All non-corrosion-resistant valves shall be coated externally in accordance

with manufacturer‟s standards, unless otherwise agreed.

8.2 Carbon steel valves shall be painted with two coats of inorganic zinc silicate primer ( Min. 35 micron per coat) . .

8.3 Flange faces, weld bevel ends and exposed stems shall not be coated.

8.4 Parts and equipment that have bare metallic surfaces shall be protected with a rust preventative that can provide protection at temperatures up to 50 °C (122 °F).

8.5 After testing, all valves shall be drained and dried thoroughly. Valve shall

be suitably painted as above / vendor‟s standard approved specifications. 8.6 Flanged, threaded and welding ends shall be blanked off to protect the

gasket surfaces, welding ends and valve internals during shipment. Machined surfaces shall be protected against corrosion during shipment and storage.


23

8.7 Valves shall be protected from rust, corrosion and any mechanical damage during Transportation, shipment and storage. The packages shall be sea-worthy when required to be transported by ships.

8.8 Rust preventive on machined surfaces shall be easily removable with a Petroleum solvent.

8.9 Each end of valves shall be protected with the following materials:

Flange Face : Wood, Wood fiber, Metal or Plastic cover

Beveled End : Wood, Wood fiber, Metal or Plastic cover

SW & SCRD End : Plastic Cap

The ends shall be securely attached to the valve ends by bolting, steel

straps, Steel clips or suitable friction-locking devices. The design of the covers shall Prevent the valves from being installed unless the covers have been removed. A warning label shall be attached to the protective cover with instructions to remove, prior to installation, material from inside the valve that secures or supports the disc.

Each valve shall be wrapped in a polythene / impervious sheet &

packed separately in wooden crate, properly secured to prevent damage during transportation. Each box shall be clearly marked, valve size, location of dispatch, Purchaser company’s name , UP marking & ―fragile‖ warning.

The valve boxes shall be put in a large container for transportation as

per manufacturer’s standards separately for each Purchaser Company & location of dispatch.

8.10 The Plug valves shall be shipped in the fully open position. While, gate valve shall be shipped with the gate in the fully closed position.

8.11 Valves of size DN 200 (NPS 8) and larger shall be provided with lifting

points,Unless otherwise agreed. The manufacturer shall verify suitability of the lifting points.


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9 SPARES & SPECIAL TOOLS : 9.1 Vendor shall submit list of standard spares of valves & actuators along with unit rates with validity for 2 years. 9.2 Vendor shall submit list of special tools, if required for maintenance of

valves along with unit rates with validity of 2 years.

10 COMMISSIONING ASSISTANCE & WARRANTIES :

10.1 Vendor shall arrange to depute his commissioning engineer to locations of IOCL/BPCL/HPCL as covered in Purchase order for attending to any teething problems related to valve operations, if any, without any extra charges. The representative shall ensure that the valve is commissioned successfully.

10.2 Vendor shall provide warranty for the performance of valves for 18 months

from date of dispatch or 12 months from date of installation, whichever is later subject to not exceeding 24 months from date of dispatch.

10.3 Manufacturer shall have / develop adequate service support in India to

provide technical after sales service in India with in 48 hrs. Notice & shall guarantee supply of parts, services for at least 10 years for all valves supplied by way of an undertaking.

11 TRAINING :

11.1 Site training ( At Owner works) : The scope of work of vendor shall include co-ordination, arranging faculty, bring them to Owner's training center, arranging lodging and boarding, transportation etc. for Training of Owner's personnel. Owner's responsibility will be limited to providing Training hall with all requisite training aids and arranging food / snacks during training session.

The training program will comprise of classroom training and explanation of details of valves. The group to be trained will comprise of persons from all disciplines of maintenance, operation and other associated departments.

The specialist installation / commissioning engineer(s) of valves will conduct the training covering operational and maintenance aspects.


25

Training shall be arranged for Multidisciplinary group. Vendor shall arrange to provide one day trainings at site in all the regions to appraise Purchaser‟s engineers / operators on operations & maintenance of valves.

(One day Training at 10 locations in India for 12-15 persons each)

11.2 Training at vendor works. The scope will include co ordination for

arranging training for officers at vendor works for 3-4 days. The group deputed for training will comprise of two multi disciplinary groups of 15 officers each drawn from operation, maintenance departments of all the 3 purchasing companies with a group leader.

All lodging and boarding and traveling expenses of IOCL/BPCL/HPCL

personnel will be borne by owners. However all requisite training material like literature/documents shall be

provided by the vendor. Vendor shall include cost of such training in their offer.


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B) SPECIFICATION FOR ELECTRICAL MOTOR OPERATED VALVE

ACTUATORS

1.0 SCOPE : The scope of this specification covers design, manufacture, assembly, shop

testing and supply of electrical motor operated valve actuators intended for fully / partially opening and closing valve duty.

2.0 CODES AND STANDARDS : 2.1 The equipment shall comply with the requirements of latest revision of the

following standards issued by BIS (Bureau of Indian Standards) unless specified otherwise:

IS 9334 Electric Motor Operated Actuators

IS 13947 (Parts –1, 3, 4&5)

Low Voltage Switchgear

IS4722 Rotating electrical machines – Specification

IS-325 Three-phase Induction Motors

IS 2148 Flameproof enclosures for electrical apparatus

IS 4691 Degrees of protection provided by enclosure for rotating electrical machinery

EN 50018

Electrical Apparatus for Potentially Explosive Atmosphere [EEx(d)]

IEC 60079 Electrical apparatus to explosive gas atmosphere.

IEC 60529

Classification of degrees of protection provided by Enclosures (IP codes).

IEC 60801

Electromagnetic compatibility of Industrial-Process management and control equipment

IEC 61508

Functional Safety of Electrical/Electronic/ Programmable Electronic Safety Related Systems

IEC 61511

Functional safety – Safety Instrumented Systems for the Process Industry Sector


27

2.2 In case of imported equipment, the standards of the country of origin shall be applicable if these standards are equivalent or more stringent that the applicable Indian standards.

2.3 The equipment shall also conform to the provisions of Indian Electricity Rules

and other statutory regulations currently in force in the country. 2.4 In case Indian standards are not available for any equipment, standards issued

by IEC/ BS/ VDE/ IEEE/ NEMA or equivalent agency shall be applicable. 2.5 In case of any contradiction between various referred standards / data sheets

and statutory regulations, the following order of decreasing priority shall govern:

- Statutory regulations - Data sheets & Job specifications - Codes and standards - Manufacturer‟s standards

3.0 GENERAL REQUIREMENTS : 3.1 The offered equipment shall be brand new with state of the art technology and a

proven field track record. No prototype equipment shall be offered. 3.2 Vendor shall ensure availability of spare parts and maintenance support services

for the offered equipment for at least 15 years from the date of supply. 3.3 The vendor shall be responsible for design, engineering and manufacturing of the

complete actuator to fully meet the intent and requirements of this specification and attached data sheets.

4.0 TECHNICAL SPECIFICATIONS Each MOV actuator shall include the motor, actuator unit, gears, position

indicators, limit switches, hand wheel, electrical starter and controls, terminal box etc. as a self-contained unit. The actuator shall be sized to provide adequate torque and/ or thrust to ensure the complete intended travel of the valve under the worst operating and electrical power supply conditions.


28

4.1 MOTOR: 4.1.1 The motor shall be 3-phase squirrel cage induction type unless specified

otherwise in the data sheet. It shall have totally enclosed non-ventilated construction.

4.1.2 The motor shall be designed for valve actuator service with high starting torque

and shall be suitable for Direct on line starting. It shall be rated for S2-15 minute duty and shall conform to IS 325 or equivalent international standards.

4.1.3 The motor shall be provided with Thermostat (s) / thermister(s) embedded in the

hot spots of motor winding for protecting the motor. 4.1.4 The motor shall be suitable for operating the actuator at 75% of rated voltage at

motor terminals. 4.1.5 The motor shall have class „F‟ insulation with temperature rise limited to class „B‟

limits. Motor winding shall be treated to resist corrosive agents and moisture. 4.1.6 Motor rotor shall preferably be of die-cast aluminum and, if brazed, shall be free

from phosphorous.

4.2 INTEGRAL STARTER AND CONTROL TRANSFORMER : The reversing starter, control transformer and local controls shall be integral with

the valve actuator, unless specified otherwise in the date sheet. Solid state control of valve actuator and electrically isolated interface for remote control requirement shall be provided, wherever these features exist in manufacturer‟s design. The integral starter shall be supplied with the following devices: a) Electrically and mechanically interlocked revering contactors for opening

and closing operations. b) Control transformer with necessary tappings and protected with suitable

easily replaceable fuses. c) Terminal block for external cable connection fully prewired for internal

devices of valve actuator. d) MOV actuators operating with AC power supply shall be provided with

Instantaneous Phase reversal protection.


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4.3 INTEGRAL PUSH BUTTON, SELECTOR AND CONTROL DEVICES :

The following local control devices shall be provided integral with the MOV actuator: a) Push buttons for “Opening/ Closing/ Stop” or alternatively “Open/ Close”

selector switch shall be provided. OPEN & CLOSE push buttons should be of green & red color respectively. Close operation shall be push type & Open operation shall be press & rotate type

b) “Local/ off/ Remote Selector switch shall be pad-lockable in each position. c) Local continuous position indication from “Valve fully open” to “Valve fully

closed” position, which may be of analogue or digital type using mechanical indication/ Indicating lamps /LEDs.

4.4 TORQUE AND TRAVEL LIMIT SWITCHES :

Torque limit switches shall be provided to protect the motor from over-loading by

cutting-off the power supply to motor during opening and closing operations. The limit switches shall be preset. However, it shall be possible to set the value of maximum torque during closing from 50% to 100% of rated torque of actuators. Travel limit switch shall be provided to cut-off the power supply to the motor at the end of preset limit of valve travel. The switches shall be provided with requisite number of potential-free contacts for valve actuator operation and for indication on remote panels as specified in data sheet. Instead of mechanical torque limit switches, magnetic pulse counter / encoders to measure and control the smoke of actuator may be provided, wherever this feature exists in manufacturer‟s design.

4.5 CONTROL FACILITIES:

The internal controls and monitoring circuits shall be incorporated within the integral starter along with transformer and control unit of valve actuator. Following remote control and monitoring facilities are to be provided as a minimum:

_ MOV open command

_ MOV close command _ MOV open status indication _ MOV close status indication _ Position status of Remote / Local / Off selector switch


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Remote control facility shall be provided for all the actuators. The remote control circuits shall be powered from internally derived control supply voltage. In order to cater to remote control and indication requirements for „Position of Remote / Local / Off selector switch‟, an additional Monitoring relay/ auxiliary relays shall be provided as a part of the valve actuator. As an alternative, a common status contact indicating the availability of the MOV actuator for remote control may be provided by monitoring the following: - Loss of one or more phases of power supply - Loss of control circuit supply - Selector switch in local mode - Local stop push button set to 'Off' - Motor thermostat tripped - Any other local fault / abnormal condition.

4.6 Hand Operation:

A hand wheel with hand‟ auto lockable lever shall be provided for emergency operation of the MOV. The energisation of the motor shall automatically re-engage power operation.

4.7 Two wire control System :

MOV actuators shall be suitable for 2-wire control system. These actuators shall have general purpose FCU card embedded for communicating with any make of master station or the FCU shall also be compatible for direct communication on open type international standard 2 wire serial communication protocols/ modbus for serial communication directly. Individual field units connectable to a master station through a single 2-core cable loop for control and monitoring of the MOVs Bidders shall provide open communication protocol (eg. MODBUS RTU, FIELDBUS etc ;) for 2 wire connectivity. Bidders are required to interface their 2-wire control systems with owner supplied PLCs (provided with corresponding protocol interface card) as applicable. Each field unit / MOV actuator shall be addressable through a unique address code. All the diagnostics & control features required as per these specifications shall be available through 2 wire system

4.8 REMOTE POSITION INDICATOR: If requirement of remote position indication is specified in the data sheet, a 4-20

mA remote position transmitter shall be provided in the valve actuator and a continuous position indicator for mounting in purchaser‟s remote panel shall be


31

supplied as a loose item. The remote position indicator shall continuously indicate the position of travel of the valve.

4.9 NAMEPLATE: Each motorized valve actuator shall be provided with a stainless steel nameplate

furnishing the following details, attached firmly to it at a place convenient for reading: a) Actuator tag number as per data sheet b) Motor kW rating, motor time rating, motor supply voltage, nominal motor

phase current, auxiliary switch rating c) Maximum torque setting d) Actuator enclosure type, lubricant type e) Actuator type, wiring diagram number/ catalogue number, actuator serial

number A separate nameplate shall be provided for hazardous area application.

4.10 The enclosure of complete MOV actuator including motor, integral starter, control

transformer unit and all control devices shall have minimum IP-65 degree of ingress protection.

4.11 WIRING AND TERMINALS:

All devices provided in the actuator shall be wired up to the terminal block. The contacts for remote operation and indication shall also be wired up to the terminal block. Minimum 10% spare terminals shall be provided for future interlocks. Internal wiring for power and control circuits shall be appropriately sized for MOV actuator rating. Each wire shall be identified at both ends using PVC ferrules. The terminal compartment shall be separated from the inner electrical components of the actuator by means of a watertight seal so that the actuator electrical components are protected from the ingress of moisture and foreign materials when the terminal cover is removed during installation and maintenance.

4.12 Vendor shall be solely responsible for the compatibility of the MOV actuator with

the valve and for the selection and sizing of various electrical devices and components in the actuator.

4.13 The actuator shall be provided with minimum three adequately sized cable

entries viz., one for power cable and two for control cables. However, the actual number of control cable entries in actuator with 2-wire control system shall be provided based on job requirements as specified in data sheets/ specification for


32

control systems for MOVs. Suitable double compression cable glands shall be provided with each actuator for all cable entries and sealing plugs for all control cable entries. The cable glands and plugs shall be made of Nickel-plated brass.

5.0 REQUIREMENTS FOR HAZARDOUS AREAS:

Hazardous Area Classification and Protection : Instruments located in hazardous area shall be certified to meet or exceed the electrical hazardous area defined by Area classification.

The actuator accessories used shall be flame proof and suitable for hazardous area of Zone 1, Group IIA/IIB, T3 or better for applications. Additionally all valve associated instruments shall be weatherproof to IP65./PI67 Instruments certified for use in the specified hazardous area classification shall be recognized by authority like FM,CENELEC, PTB, BASSEFA, ATEX , CCOE/PESO etc.

Actuators meant for hazardous areas shall meet the requirements of IS 2148,

IEC 79 or equivalent international standards . The manufacturer shall possess valid test certificates issue by a recognized independent test house (CIMFR/ Baseefa/ LCIE/ UL/ FM or equivalent) for the offered actuators. All indigenous equipment shall conform to Indian standards and shall have been tested and certified by Indian testing agencies. All equipment (indigenous and imported) shall also have valid statutory approvals as applicable for the specified hazardous locations from Petroleum and Explosives Safety Organization (PESO)/ CCE or any other applicable statutory authority. All indigenous flameproof equipment shall have valid BIS license and corresponding marking as required by statutory authorities.

5.2 Apart from the nameplate indicating the Tag NO. a separate nameplate shall also

be provided on each actuator to indicate the details of the testing agency (CIMER or equivalent), test certificate number with date, statutory approval number with date, approval agency (PESO/ CCE/ DGMS or equivalent), BIS license number with date, applicable Gas group and Temperature class etc. the nameplate shall be riveted/ fixed with screws and not pasted. In case any of the standard details listed above are embossed on the enclosures, the same need not be repeated.

6.0 INSPECTION, TESTING AND ACCEPTANCE : 6.1 The equipment shall be subject to inspection by Owner or by an agency

authorized by the owner. Manufacturer shall furnish all necessary information concerning the supply to Owner. During the course of manufacturing, the purchaser or his authorized representative shall be free to visit the works and


33

assess the progress of work and the manufacturer shall render him all possible assistance to do so.

6.2 Following routine and acceptance tests shall be carried out at the manufacturers‟

works under his supervision and at his own cost for all the actuators in line with QAP approved by the owners.

6.2.1 ROUTINE TEST : Functional and calibration test for torque and limit switches

6.2.2 ACCEPTANCE TESTS :

Response time test

Variation of supply voltage

Variation of frequency

Tests for motor (As per relevant IS/ IEC)

Life test

Test on output shaft

FOLLOWING TESTS SHALL BE PROVIDED PRIOR TO SHIPPING:

Actuator operation, Cycle (open-close) each valve with its actuator at least five times, for proper actuator operation. Verify that valve position coincides with position indicators.

Opening -closing position

Actuator output speed & Open-Close time

Actuator travel setting

Operational torque test as per API 609. The maximum measured torque shall be less than 75 % of the design torque specified by the valve manufacturer for actuator sizing.

FAT and SAT for the system Two weeks‟ notice shall be given to Owner for witnessing the final testing of the complete assembly to ensure satisfactory operation of the MOV actuators. Type test certificates shall be furnished with bids. Final acceptance of MOVs at site shall be subject to successful testing of the MOV actuators with the valves.

6.3 Type test certificates, original drawings referred in certificates and statutory

approval certificates and BIS license, where applicable, shall be shown to the


34

inspection agency on demand. The certificates and BIS license must be valid at the time of dispatch.

6.4 Test certificates of bought-out components shall be shown to the inspection

agency on demand. 7 PACKING AND DISPATCH :

All the equipment shall be divided into multiple sections for protection and ease of handling during transportation. The equipment shall be properly packed for the selected mode of transportation, i.e. by ship, rail or trailer. The equipment shall be wrapped in polythene sheets before being placed in crates/ cases to prevent damage to finish. The crates/ cases shall have skid bottoms for handling. Special notations such as “Fragile‟. “This side up”, “Center of gravity”, “Weight‟, “Owner‟s particulars‟, „PO no.‟ etc. shall be clearly and indelibly marked on the packages together with other details as per purchases as per purchase order. The equipment may be stored outdoors for long periods before installation. The packing shall be completely suitable for outdoor storage in areas with heavy rains and high ambient temperature unless otherwise agreed. In order to prevent movement of equipment/ components within the crates, proper packing supports shall be provided. A set of instruction manuals for erection, testing and commissioning, a set of operation and maintenance manuals and a set of final drawings shall be enclosed in a waterproof cover along with the shipment. These precautions shall be read in conjunction with similar specifications for valves.

8 SPARES & SPECIAL TOOLS :

8.1 Vendor shall submit list of standard spares of Actuators along with unit rates with validity for 2 years. 8.2 Vendor shall submit list of special tools, if required for maintenance of Actuators along with unit rates with validity of 2 years. 9 COMMISSIONING ASSISTANCE :

Vendor shall arrange to depute his commissioning engineer to each locations of

IOCL/BPCL/HPCL as covered in Purchase order for supervising commissioning activities of actuators without any extra charges. The representative shall ensure that the actuator is commissioned successfully.


35

10 WARRANTIES :

10.1 Vendor shall provide warranty for the performance of Actuators for 18 months from date of dispatch or 12 months from date of installation, whichever is later subject to not exceeding 24 months from date of dispatch.


36

11.0 DATE SHEET FOR MOV ACTUATOR : PURCHASERS DATA 1.0 SITE CONDITIONS

S.NO.

1.1 Altitude Less than 1000 m Above MSL

1.2 Design ambient temperature

-10 deg. To + 55 deg. C

1.3 Humidity max. 100 %

1.4 MOV Tag Nos Will be intimated after award of contract.

2.0 SYSTEM CONDITIONS :

S.NO.

2.1 Supply Voltage 415V+ 10%, 3-phase AC for MOV

2.2 Supply Frequency

50 Hz + 3%

2.3 System Earthing Solidly Earthed

3.0 OPERATING ENVIRONMENT :

S.NO.

3.1 Area Classification : Zone 1

3.2 Gas Group : IIA/IIB

3.3 Temperature Class : T3

3.4 Construction : Flameproof Ex(d)

3.5 Ingress Protection : IP65

3.6 Painting : Epoxy base

3.7 Whether ―K-Mass‖ type or equivalent fire proofing required

: No

3.7.1 For MOV Tag Nos : Not Applicable.

3.7.2 With fireproof rating : Not Applicable

4.0 Valve Duty , Mode of Control and Devices for Control

4.1 Valve duty

a. Fully open and fully closed : Yes.

b. Partially open and partially closed : No

Control Requirement

: Local & Remote for all MOVs

Local / Remote / Off selector switch on MOV Actuator

: Required

Compatibility for interfacing with 2 wire control system

: Required


37

Setting adjustable parameters of Actuator ( for 2 wire control system)

: From field & remote thru Master Control Station / PLC for 2 wire control

Continuous position indication

Local Mechanical / LCD indication is required.

Remote – Potentiometer / transducer for remote continuous indication

Required in control room thru‟ Master Control Station

Intermediate travel limit switch Required

Potentials free contacts for indication on remote panel and other interlocks

For Valve Open Position Required

For Valve Closed Position Required

For remote indication or position of Local / Remote selector switch

Required

For availability of MOV actuator Remote Operation ( contact from monitoring relay)

Required

For indicating valve position in progress Not required

Remote emergency stop push button for Stopping Actuator

Required.

DCS/PLC interface for Remote Control / Indication

Remote Indication required for all MOVs

time of operation

- Opening 90 sec or as per design of valve

- Closing 90 sec or as per design of valve

Make of MOV Actuator Rotork,Auma or Limitorque

Double Compression Glands & plugs ( for unused entries ) , to be supplied with the Actuator

Flame and weather Proof

Test and Approval Certificates for Flame Proof Actuators

For Indigenous make MOV Actuators

Refer technical specifications of Electrical MOV Actuators

For Imported make MOV Actuators

Refer technical specifications of Electrical MOV Actuators

Submission of Type Test Certificates -

Yes


38

Notes : 1. N.A. denotes “ Not Applicable.” 2. Area Classification Zone, Gas group and Temperature class indicated at 5 Nos.

3.1 to 3.3 above refer to IS/IFC standards.

3. Two separate earthing bosses shall be provided in each actuator. All the actuators shall be controlled through 2 wire control station. The Master station , if available with the owner, the new actuators shall be hooked to the existing Master station. Vendor to quote rates including Internal Field Control Unit (IFCU) for actuators suitable for 2 wire control system. Supply of master station is not in the scope of this tender.

4. The purchaser shall provide single point power supply to the actuator as per

S.No.2 above. Any other control supply voltage required shall be internally derived by the manufacturer within the actuator.

5. Vendor shall furnish complete data as per Part-II of this data sheet for each MOV

Actuator along with the offer. 6. Remote Input signals for opening / closing / stopping the MOV shall be

provided through the momentary closing of separate potential free contacts in owner‟s panel. Necessary controls required for running the motor for the complete opening / closing sequence of the valve using such input signals shall be provided by manufacturer in the actuator.


39

12.0 Vendor data requirement MOV Actuator

S.No. Description With Bids Post order Final Documents

For Review

For Ref./ Records

1 Vendor Drawing / Document Submission Schedule

* *

2 List of deviations, if any, to MR requirements

3 Data Sheets (duly filled in * * *

4 G.A and mounting details of actuators * *

5 Wiring and Connection diagrams * *

6 QA Plan of Vendor * *

7 Shop Inspection Plan and Testing Procedure

* *

8 Test Records *

9 Type Test Certificates for Flameproof / Explosion proof equipment

* *

10 Recommended maintenance spares with prices

*

11 Equipment storage procedure *

12 Data Books / Manuals

a. Installation Manual and Standard

b. Operating/Maintenance Manual

c. Catalogues / Brochures indicating complete technical details and data for actuator selection

*

* * *

13 Details of fireproofing, if specified in data sheet

* * *

Notes :

1. Vendor shall furnish soft copy of all drawings in Auto Cad version 14.0 / 2000

and all documents in MS Office 2000, as part of final documentation. 2. All technical details and documents furnished with bids shall be treated as data

for engineering. These shall however, be subject to Purchaser‟s review after order placement and bidder shall comply to MR/Tender requirements without any cost & time implication.


40

QAP for DBB VALVES SCOPE OF INSPECTION

S. No.

STAGE/ Activity

COMPONENT

CHARACTERISTICS

METHOD OF

CHECK

QUANTUM OF

CHECK

REFERENCE DOCUMENTS

ACCEPTANCE NORMS

RECORD SUB VEN DOR

VENDOR

TPI

1. Incoming raw Materials / components

Raw material for fabrication of valve body, plate, flange

etc

Surface Quality Visual As per Mfg Test plan and

applicable code

As per Mfg Test plan and applicable code

As per Mfg Test plan and applicable code

Inspection Report

W W R

2. do do Dimensions Measurement

As per Mfg Plan

Approved Drawing

Approved Drawing

Inspection Report

W W R

3. do do Chemical & Mech. Prop.( Hardness,

bend, Tensile etc.)

Review of Vendor

TC

All Heats As per relevant Material

Spec

As per relevant Material

Spec

Inspection Report Vendor

TC

W W R

4. WPS and WPQ QAP

As per applicable code /specification


5.

Welding of valve body, bottom plate

& flanges

Valve body Weld joint fit-up Visual 10% of qty. as per data sheet

(wherever applicable)



W W R

6.

do do Radiography Visual 10% of qty. as per data sheet




W W R

7. do do Ultrasonic Examination

Visual 10% of qty. as per data sheet




UT Scan Report

W R R

8. Bought Out, Finished &

Sub contract items

Stems, Gaskets

Gear units, Fasteners etc

Surface Defects Visual As per Mfg. Sampling

Plan

App DWG / Relevant Std.


Inspection Report

W R R


41

9. Bought Out, Finished &

Sub contract items

Stems, Gaskets

Gear units, Fasteners etc

Dimensions Measurement As per Mfg. Sampling

Plan



Inspection Report

W R R

10. do do Physical and chemical properties

Review of TC of supplier

As per Mfg. Sampling

Plan



Inspection Report

W R R

11. do thermal relief valve

Hydro-test of Review of TC of supplier

(100% )

As per Mfg. Sampling

Plan



Inspection Report

W R R

12. Product Evaluation &

Testing

Finished Valve

Hydrostatic shell test

100 % of the valves of all

sizes & types

As per applicable

code /specification /app drawing

As per applicable code

/specification


Test Report

- W R

13. do do

Hydrostatic seat test

100 % of the valves of all

sizes & types

do As per applicable code

/specification


Test Report

- W W

14. do do

Additional seat test 10 % of the valves of all

sizes & types


/specification


Test Report

- W W

15. do do

Anti-static testing 5 % of the valves of

each size & type


/specification


Test Report

- W R

16. do do

Torque/thrust functional testing

1 % of the valves of

each size & type


/specification


Test Report

- W R

17. do do

Drive train strength test

1 % of the valves of

each size & type

do


/specification


Test Report

- W R

18. do do

Fire Safe testing As per applicable

specification

As per applicable

code /specification /app drawing


/specification /app drawing


/specification /app drawing

Test Report

- W R


42

19. Product Evaluation &

Testing

Finished Valve

Functional/ Operational

Test (For Motor /Actuator Operated)

As per DWG. 100% App DWG App DWG Test Report

------ W H

20. Final Inspection

Finished Valve

Visual (TC Verification, SL. No. Marketing

Flange finish, Tag No.) Bevel

Dimensions & Special

Requirement in PO

Visual & Std.

Measuring Instruments DP & MPI Of bevel Surfaces

Visual 100% and

dimensions at random

App DWG App DWG Inspection Report

------ W H

21. Packing Finished Valve

------ At random ----- As per dispatch instructions

App DWG & Spec

---- ------- W R

22. 15 Strip Check, Differential hardness

(see notes)

Finished Valve Verify Components Visual 1 Valve per Type/Size &

order

App DWG / PR App DWG & Spec

Inspection Report

--- NA

NA

Legends: H-Hold (Offer for Witness & obtain clearance),W-Witness, R-Review, A-Approval, I-Information, X-Submit, PO-Purchase Order, PR-Purchase Requisition, Differential hardness – surveillance check & to be taken up before lapping is done normally, , DP-Dye Penetrate Test, UT-Ultrasonic examination, All the NDT-Leak testing/Heat treatment/Special manufacturing procedures have to be specially approved or only previously approved procedures have to be used. In case of conflict between purchase specification, purchase specification shall be applicable. This document describes generally the requirements pertaining to all types of valves. Requirements specific to the item are only applicable. Abbreviation:

WPS - Welding Procedure Specification

WPQ - Welders Performance Qualification

QAP - Quality assurance plan

Manufacturing – Mgf

Specification – Spec

App DWG - Approved Drawing

TC – Test Certificate Note: This QAP is to be further developed by Vendor in line with the tender specifications, applicable codes & standards and to submit for owner’s approval before manufacturing

Tender: Global Tender (Ref DBBV BPCL) for procurement of approx 86 nos. of Double Block & Bleed and Double Isolation Gate / Plug Valves conforming to API 6D. Tender Ref No: DBBV BPCL System No: 10432

1 | P a g e

S.No Technical Queries on Electric Actuators Vendor Response

1. Please find attached the Electric Actuator Sizing Sheet (as Annexure-1). Bidder to furnish the data as asked in the Sizing sheet. It is to be noted that the offered actuators are not designed in accordance with the following parameters specified in tender specifications:

• Max. pressure differential as 10.5 Kg/Cm2 across the valve is to be considered for Valve Brakeaway torque calculations for the following scenarios -

o Fully open position to fully close position at max. flow rate.

o Fully close position to fully open position.

• Factor of Safety as 2 times of maximum valve brakeaway torque.

2. Bidder to submit, Make / Model No. of the selected Electric Actuators along with its de-codification sheet as per the sizing sheet.

3. Bidder to furnish PESO / CCOE / CMRI certificate for flameproof enclosure (valid as on date).

• For Electric Actuators

• For Limit Switches

4. Bidder to submit valid weatherproof certificate (min IP-65) for the offered make of electric actuators.

5. Bidder to submit their deviation / compliance statement as against tender specifications for the Electric Actuators.

6. Bidder to confirm following-

• availability of in-built position transmitter with LCD display in the actuator.

• Availability of MODBUS RTU communication at actuator

• Availability of hardwired contacts (potential Free) for Open/ close/ remote-Local status of DBBV.

• ESD Port at Actuator.

7. Bidder to confirm that the manual handwheel provided at

Tender: Global Tender (Ref DBBV BPCL) for procurement of approx 86 nos. of Double Block & Bleed and Double Isolation Gate / Plug Valves conforming to API 6D. Tender Ref No: DBBV BPCL System No: 10432

2 | P a g e

S.No Technical Queries on Electric Actuators Vendor Response

actuator shall meet the torque requirement as 360 N (80 lbf). In this regard bidder to confirm clause 4.6 “Hand Operation” of tender specifications for electric actuators.

8. Bidder to confirm that 2 separate earthing bosses are provided in each actuator.

9. As per clause 8 “Spares & Special Tools” of tender specifications for electric actuators, bidder to furnish details/ list (only) of standard spares and special tools required.

Valve

Catalogue

No.

Valve

Brakeaway

torque *

(Nm)

(See Note

1 Below)

Gear

Box

Model*

Gear

Ratio

Number of

Revolutions

Mechnical

advantage

Actual

I/P

torque at

Gear

Box

(N-m)

Actuator

Make /

Model *

Max.

Torque *

(Nm)

RPM

Opening

/ Closing

Time

(Sec)

Actuator KW

Rating

(KW)

Vendor to

Specify

Vendor to

Specify

Vendor

to

Specify

Vendor

to

Specify

Vendor to

Specify

Vendor to

Specify

Vendor

to

Specify

Vendor to

Specify

Vendor to

Specify

Vendor

to

Specify

Vendor

to

Specify

Vendor to

Specify

1 6 150 2.0

2 8 150 2.0

3 10 150 2.0

ANNEXURE-1 Electric Actuator Sizing Sheet

Note 1:Max. pressure differential as 10.5 Kg/Cm2 across the valve is to be considered for Valve Brakeaway torque calculations for the

following scenarios -

(a) Fully open position to fully close position at max. flow rate.

(b) Fully close position to fully open position.

* Bidders to submit documentary evidence for the same.

Tender: Global Tender (Ref. DBBV BPCL) for procurement of approx 86 nos. of Double Block & Bleed and Double Isolation Gate / Plug Valves conforming to API 6D.

Tender No: DBBV BPCL

System No: 10432

Sl.

no

Valve

Size

(Inch)

Valve

Class

Factor of

Safety

(FOS)

Valve

Brake

Away

torque

with

FOS

(N-m)