TECHNICAL SUPPLY CONDITIONS FOR PIPING …tenders.hpcl.co.in/tenders/tender_prog/TenderFiles/6186/Addendums...ASME American Society of Mechanical Engineers CS ... B16.25-2007 Butt-Welding

EPMC SERVICES FOR URAN-CHAKAN-

SHIKRAPUR-LPG PIPELINE PROJECT

Doc No.:272261-500-SP-PIP-009 Rev: 0 Page 1 of 30

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TECHNICAL SUPPLY CONDITIONS

FOR

PIPING VALVES

Hindustan Petroleum Corporation Ltd

Hindustan Bhavan

8, S.V. Marg

Ballard Estate

Mumbai 400 001

Mott MacDonald Private Limited,

Mott MacDonald House,

44/45, Street No. 14,

MIDC, Andheri (East),

Mumbai – 400 093.

India





TECHNICAL SUPPLY CONDITIONS

FOR

PIPING VALVES

Client HINDUSTAN PETROLEUM CORPORATION LTD.

MMCI Project No. 272261

Issue and Revision Record:

Rev Date Originator Checked Approved Description

0 29.03.2011 JAT IYS SNA Issued For Tender

Group Disclaimer

“This document is issued for the party which commissioned it and for specific purposes connected with the

above-captioned project only. It should not be relied upon by any other party or used for any other purpose.

We accept no responsibility for the consequences of this document being relied upon by any other party, or being

used for any other purpose, or containing any error or omission which is due to an error or omission in data

supplied to us by other parties”.





List of Contents Page No

1 Scope 4

2 Abbreviation and Definition 4

3 Order of Precedence 5

4 Codes, Standards and Specifications 5

5 Exceptions to Specified Requirements 7

6 General Requirements 7

7 Construction Features 7

8 Gear Operator Requirements 10

9 Test & Inspection 10

10 Markings 12

11 Painting & Coatings 12

12 Substitutions and Variations 13

13 Packing 13

14 Certification & Traceability 13

15 Maintenance Spares 14

16 Despatch 14

17 Documentation 14

18 Guarantee 15

Annexure I: Gate & Globe Valves 16

Annexure II: Check Valves 19

Annexure III: Ball Valves 21

Annexure IV: Butterfly Valves 23

Annexure V: Plug Valves 25

Annexure VI: Non Destructive Examination (NDE) for Valve Castings 27

Annexure VII: Pressure Testing Requirements 29





1 Scope

This specification covers the technical requirements for manufacture, inspection, testing &

dispatch requirements of commonly used valves for process & utility services. This document

specifies the minimum requirements governing the supply of all piping valves, whether

supplied as bulk materials or as part of an equipment package unit including auxiliaries such as

bypass, vent drain and sealant injection valves. It forms an integral part of any Enquiry,

Material Requisition or Purchase Order package for piping components and shall be read in

conjunction with the documentation referenced therein.

2 Abbreviation and Definition

2.1 Abbreviation

ANSI American National Standards Institute

API American Petroleum Institute

ASTM American Society for Testing and Materials

ASME American Society of Mechanical Engineers

CS Carbon Steel

LPG Liquefied Petroleum Gas

LTCS Low Temperature Carbon Steel

NB Nominal Bore

NDT Non Destructive Testing

NPS Nominal Pipe Size

OD Outside Diameter, Specified

QCP Quality Control Plan

WT Wall Thickness, Specified

2.2 Definitions

The following terms are used in this specification:

Manufacturer/Vendor shall mean the manufacturer or supplier of the

Materials covered by this Specification.

Owner shall mean Hindustan Petroleum Corporation Limited.

Consultant shall mean Mott MacDonald Consultant India Pvt. Ltd.

Shall shall indicate a mandatory requirement.





3 Order of Precedence

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

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

precedence:

• The Purchase Order Specification, Enquiry or Material Requisition.

• This Document.

• Other reference Project Specifications referred to in this Document.

• Referenced Codes and Standards.

4 Codes, Standards and Specifications

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

specifications as available at the date of contract award:

A) American Society of Mechanical Engineers (ASME)

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

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

B16.1-2010 Gray Iron Pipe Flanges & Flanged Fittings.

B16.5-2009 Steel Pipe Flanges and Flanged Fittings.

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

B16.10-2009 Face to Face and End to End Dimensions of Valves.

B16.11-2009 Forged Steel Fittings, Socket Welding and Threaded.

B16.14-1991 Pipe Plugs.

B16.20-2007 Metallic Gaskets for Pipe Flanges.

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

B16.25-2007 Butt-Welding Ends.

B16.34-2009 Steel Valves - Flanged, Threaded and Welding End.

B16.36-2009 Orifice Flanges.

B16.47-2006 Large Diameter Steel Flanges

B16.48-2010 Steel Line Blanks

B18.2.1-2010 Square and Hex. Bolts and Screws (Inch Series).

B18.2.2-2010 Square and Hex. Nuts (Inch Series).

B31.1-2010 Code for Power Piping.

B31.3-2008 Code for Pressure Piping – Chemical Plant and Petroleum

Refinery Piping.

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

B36.19-2004 Stainless Steel Pipes.

B46.1-2009 Surface Textures.

B) Manufacturers Standardisation Society (MSS)

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

SP-43 :2001 Wrought Stainless Steel Butt-Welding Fittings.

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

and Other Piping Components.

SP-95: 2006 Swaged Nipples and Bull Plugs.

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

threaded and Butt-Welding Ends.





C) American Petroleum Institute (API)

API 594-2004 Wafer Type Check Valves, Steel.

API 598-2009 Valve Inspection and Testing.

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

API 600-2009 Steel Gate Valves, Flanged and Butt-Weld Ends.

API 602-2009 Compact Steel Gate Valves.

API 607-2010 Fire Test for Soft Seated Quarter Turn Valves.

API 608-2008 Metal Ball Valves - Flanged and Butt-Welding Ends.

API 609-2009 Butterfly Valves, Lug and Wafer Type.

D) British Standards Institute (BS)

BS 1868-1975 Flanged and Butt-Weld Swing and Lift Type Check Valves.

BS 1873-1975 Globe Valves, Flanged & Threaded Copper Alloy, Gate, Globe

& Check Valves.

BS 5353-1989 Specification for Steel Plug Valves.

E) International Organisation for Standardisation (ISO)

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

related Products - Visual assessment of surface cleanliness.

BS EN ISO

15761-2002

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

for the petroleum and natural gas industries

BS EN 12266

Part-1-2003

Industrial valves —Testing of valves

BS EN ISO

17292-2004

Metal ball valves for petroleum, petrochemical and allied

industries

BS EN ISO

17292-2004

Steel Ball Valves for the Petroleum Petrochemical and Allied

Industries.

BS EN ISO

15761-2002

Steel Wedge, Gate, Globe and Check Valves, 4" and Smaller for

the Petroleum, Petrochemical and Natural Gas Industries.

F) Indian Standards and Regulations (IS)

G) Project Specific

All piping components shall conform to the requirements of ASME B31.4:2009 and the

relevant referenced Codes, Standards and Specifications, listed above.

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

(Material Requisition Item Number Description). In these cases, the requirements of the

Code or Standard so referenced take precedence over any conflicting requirements of ASME

B31.4 or any relevant Code or Standard referenced therein.

IS 1239 Part 1-2004 Mild Steel Tube.

IS 1239 Part 2-1992 Steel Tube Fittings.

IS 3589-2001 Steel Pipes for Water and Sewage Specification

272261-500-SP-PIP-001 Piping Material Specification

272261-500-SP-PIP-013 Valve Material Specification

272261-500-SP-PIP-003 Specification for Painting : Piping

272261-500-PH-PIP-002 Tagging Philosophy for Piping Valves





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

specification sheet shall govern.

5 Exceptions to Specified Requirements

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

the Owner / Consultant on a case by case basis for valves or materials procured within the

State of India, provided that the valves or the materials comply with applicable Indian codes

and standards.

6 General Requirements

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

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

Classes in the Project Specification. Vendor’s supplying packaged equipment shall identify

in their quotation, any piping valves within the packaged equipment which does not comply

with project specification and shall include enough details regarding the material

composition of those valves, and the services for which they are intended, to enable Owner /

Consultant’s to judge their suitability for the intended service.

6.3 Valve of sizes 1/4", 3/8", 11/4", 2-1/2", 3-1/2", 5" and 22" shall not be used.

7 Construction Features

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

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

vertical, horizontal or inclined.

7.3 Pressure temperature rating for flanged and butt welding end valves shall be as per ASME

B16.34 except for Ball, Butterfly valves and Plug valves. Valve thickness of valve body at

different locations should not be less than as calculated as per ASME B16.34. For Ball and

Butterfly valves, manufacturer’s recommendations shall be obtained before use for intended

service.

7.4 End requirements shall be as follows:-

• Butt welding ends shall conform to ASME B16.25.

• Socket welding ends shall conform to ASME B16.11.

• Threaded ends shall conform to ASME B1.20.1.

• Flanged ends shall conform to ASME B16.5 for sizes 1/2” NPS to 24” NPS.

7.5 All flanged valves shall have flanges integral (except forged valves) with the valve body.

Flange face finish shall be normally specified in the valve specification sheet as 125 AARH

etc. The interpretation for range of face finish shall be as follows.

Stock Finish : 500 µ in AARH max.

125 AARH : Serrations with 125 to 250 in AARH

63 AARH : 32 to 63 µ in AARH





7.6 For all weld end valves with bevel end as per ASME B16.25, the contour of bevel shall be as

follows:

Material Wall Thickness Weld Contour

Upto 22 mm Figure 2 Type A Carbon Steel (Except Low Temp.

Carbon Steel)

> 22 mm Figure 3 Type A

Upto 10 mm Figure 4

> 10 mm & Upto 25 mm Figure 5 Type A

Alloy Steel,

Stainless Steel &

Low Temp. Carbon Steel

> 25 mm Figure 6 Type A

Valve ends shall match thickness of the connecting pipe. Sloping of inside contour of valves

shall be done in accordance with ASME 31.4 wherever necessary to achieve this.

7.7 For flanged valves with ring joint flanges the hardness shall be as follows:

Flange Material Min. Hardness of Groove (BHN)

Carbon Steel 140

1% Cr to 5 % Cr 150

Type 304,316,321,347 160

Type 304L, 316L 140

7.8 No cast, ductile or malleable Iron, aluminium, plastic or copper bearing alloy shall be used in

Hydrocarbon service.

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

casting but not vice-versa.

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

integral stem of cast stainless steel ball valve is acceptable.

7.11 Valves shall be supplied with lever/wrench except for gear operated/motor operated valves.

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

wheel shall be either malleable iron or cast steel.

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

of valves greater than 3” shall be seal welded.

7.13 All material shall be new, clean and free from rust, pits and any defects.

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

encapsulated gaskets type body-bonnet joints are employed. Outer ring may be omitted in the

case of non-circular spiral wound gasket used in 150# valve provided the outermost layer of

spiral touches the bolts ascertaining the centring.

7.15 Where ring joint gaskets are used for the body to bonnet joint the hardness of ring of gasket

shall be lower than the valve body and bonnet.





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

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

with their stem below horizontal.

7.18 The manufacturer shall ensure the interchangeability of parts between valves of same size

and specification by specifying proper tolerances during manufacture. To check compliance

with this clause, the Inspection Engineer of Owner / Consultant shall have the authority to

select any two valves of the same size and specification and ask the Vendor to interchange

the parts and carry out necessary tests after the assembly.

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

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

7.20 Hardness requirements for trim material shall be as follows:

• Wherever body seat and disc seat materials are specified as 13% Cr, hardness of disc seat

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

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

weld deposit on ASTM A216 GR. WCB casting is acceptable for Valve Sizes 6” and

above only.

7.21 Gate and Globe valves of rating 300# and above shall have gland stuffing boxes of sufficient

depth to accommodate lantern rings in addition to gland packing.

7.22 No welding shall be done on stainless steel valves during any stage of manufacturing.

7.23 All stainless steel valve bodies shall be passivated after machining before assembly.

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

can have weld on flanges with full penetration joint and with 100% radiography of the

attached welds.

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

Fire safe test shall be as per API-607, API-6FA, API-6FD or BS 12266 Part II. The vender

has to submit test certificate for the particular design of the valve offered.

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

LLOYDS / BV / DNV / EIL / CEIL) shall be furnished to the Owner / Consultant for

Approval.

7.27 Soft-seated Ball, Plug and Butterfly valves shall be supplied with antistatic devices.

7.28 Wherever Locking Arrangement is specified in the valve MTO, the valve shall be provided

with locking arrangement such as pad lock and chain.

7.29 The padlocks supplied shall be heavy duty stainless steel weatherproof construction suitable

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

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

with the valve part number and tag.

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

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

to meet the above requirements, vendor shall offer gear operated valve.

7.31 Socket weld end valves with non-metallic seats or seals shall be provided with 100mm long

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

material specifications. These nipples shall be welded to both ends of the valve by the

Vendor, before fitting packing, seats and seals.





8 Gear Operator Requirements

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

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

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

supplied with a gear operator even if not specified in the purchase description.

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

gears in weather resistant metallic grease box manually operable by hand wheel. It shall have

a position indicator for open / close and intermediate positions.

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

kg-m, with the differential pressure across the valve equal to the cold non shock pressure

rating.

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

--------- ------------------------------------------------------------------------------------

Valve Type ASME Class Valve Size

----------------------------------------------------------------------------------------------

Gate, Globe 150 & 300 12” & Larger

600 10” & Larger

900 6” & Larger

Plug & Ball 150 & 300 6” & Larger

600 4” & Larger

900 & 1500 3” & Larger

Butterfly 150 & 300 6” & Larger

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

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

the design must be such that the wrench cannot be installed in a manner that allows the ball /

plug to be rotated more than 90°. Square stem heads are not acceptable. The lever / wrench

shall be at 90° to pipe centre line when the valve is closed. Stops shall be fitted at the fully

open and fully closed position to prevent the ball / plug from moving through more than 90°.

9 Test & Inspection

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

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

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

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

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

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

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

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

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

low-pressure air test is to be repeated.





9.4 RADIOGRAPHY OF CAST VALVES

9.4.1 Valve casting shall undergo radiographic examination as specified below:

Material Rating Size Range Radiography

24” and below NIL** 150#

26” and below* 100%

16” and below NIL** 300#

18” and below 100%

All

600# & above All sizes 100%

* No radiography is required for valve of size 26” in cooling water service.

** For sizes 24” & below in 150# and 16” & below in 300#, radiography percentage if

specifically mentioned in individual valve material spec. sheet shall govern.

9.4.2 Valves other than steel castings shall be radio graphed to the following extents:

ASME 150#, DN600 or smaller 25%

ASME 150#, DN650 or larger 100%

ASME 300#, DN400 or smaller 25%

ASME 300#, DN450 or larger 100%

ASME 600#, and higher 100%

Carbon steel to NACE requirements 100%

Stainless and high alloy steel 100%

9.5 Following Inspection procedure shall be applicable where 10 % radiography of casting is

specified:

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

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

number of casting to be radiographically examined.

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

by 9.4.1 above shall be offered for radiography. In the event of further rejection of single

casting, the whole lot shall be radiographed.

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

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

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

valve datasheet.

9.7 Valve body thickness, wherever not specified in the standard, shall be as per ASME B16.34.

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

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

ph value shall be between 6.0 and 8.0.

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





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

prior to preparation for packing.

9.11 Quality Control Plans shall be submitted for review with the bid. All valves and speciality

components will be subject to inspection in accordance with the Owner / Consultant

approved Vendor Quality Control Plan.

9.12 Vendors shall, as a minimum be ISO 9001:2008 or equal accredited, with manufacturers

preferably having ISO 9001:2008 or equal accreditation as well.

9.13 The Vendor shall provide full facilities/access for inspection by the Owner / Consultant’s

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

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

the Owner / Consultant.

9.14 Strip check is required for 1% of total ordered quantity of Gate & Globe valves (min.1 no.)

for each Valve sheet no., however strip check is not required for CS/Brass/Bronze material

valves with 13% Cr/Brass/Bronze trims.

Samples for strip check shall be selected at random and shall generally be in the highest size

in the lot.

9.15 In case of motor operated or actuator operated valves, functional / operational checks as per

the requirements of the specifications shall be made on each valve.

10 Markings

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

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

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

body.

10.2 Each valve shall have a corrosion resistant tag of stainless steel / aluminum giving size, valve

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

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

or copper which cause corrosive attack on heating.

11 Painting & Coatings

11.1 Unless otherwise specified, painting & coatings shall be done as per Clause 9.1 of API-600.

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

coated as follows :

a) Preparation: Shot blast to Swedish Standard SA2½.

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

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

accommodate design temperature of 550 C.

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

Painting Specification (Document no.:272261-500-SP-PIP-003) for detailed instruction.

11.5 Valves shall also be coded in accordance with the requirement if Doc. No. 272261-500-PH-

PIP-005.





12 Substitutions and Variations

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

they shall submit a specification of alternatives to the Owner / Consultant’s for approval at

the bid stage.

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

requirements of that order without written approval from the Owner / Consultant’s.

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

Vendor shall complete the Owner / Consultant’s “Concession Request Form” and return this

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

the change.

12.4 The Owner / Consultant’s will review each completed Concession Request Form issued by

the Vendor for the Order, for acceptance or rejection.

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

shall be sent for action.

13 Packing

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

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

welding valves shall be closed using plastic caps.

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

suitable protection for grease fittings and stem to prevent shipping damage.

14 Certification & Traceability

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

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

If more than one component is on a certificate each component must be identified by the

Contractor’s tag number and purchase order number and Manufacturer's serial number, and

certificates for each valve must be listed for that valve.

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

Contractor’s Documentation Specification covering each item supplied. All certificates shall

be fully traceable to the item covered and shall be marked with the Contractor’s order

number, item number and tag/part number. They shall be clearly legible, in the English

language.

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

manufacture of flanges and valve bodies, bonnets and pressure retaining parts shall be

furnished as test certificates of the EN 10204:3.1 type. Vendor shall confirm which parts are

considered pressure retaining and shall include a list in the bid for Contractor review.

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

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

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

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

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

also furnish EN 10204:3.1 type certificates for the Manufacture of the furnished item.





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

type shall be acceptable.

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

15 Maintenance Spares

In case of diaphragm valves, PTFE sleeved plug valves and piston valves, bidder should

furnish a complete list of maintenance spares required for two years trouble free operation

along with recommended quantities and quote the price for the same.

16 Despatch

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

Flange face. : Wood or plastic cover

Bevelled end. : Wood or plastic cover

SW or Scrd. End. : Plastic cap

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

three bolts and shall not be smaller than the outside diameter of the flange. However the

plastic cap for SW & Scrd. End valves shall be press fit type.

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

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

17 Documentation

17.1 Vendor shall submit following documents with the offer.

17.1.1 Manufacturer’s complete descriptive and illustrative catalogue / literature.

17.1.2 Detailed dimensioned cross section drawing with parts / material lists, weight etc.

17.1.3 Drawings for valves with accessories like gear operator, hydraulic / pneumatic operator,

motor, extension bonnet, extended steam with stands, bypass etc. giving major salient

dimensions.

17.1.4 One copy of the valve specification sheets signed as ‘Accepted” by the manufacturer

Deviations, if any shall be marked as applicable on the valve specification sheet.

17.1.5 If the valve is regretted or has no deviation, the manufacturer shall write clearly on valve

specification sheets as “Regret” or “No Deviation”.

17.1.6 On failure to submit documents as specified in clauses 17.1.1 to 17.1.5 above, the offer is

likely to be rejected.

17.2 The following documents shall be submitted after placement of order.

17.2.1 Vendor shall submit for review drawings mentioned in clauses 17.1.1 & 17.1.3 before start of

manufacture. No other drawings shall be submitted for review.

17.2.2 Test report shall be supplied for all mandatory tests as per the applicable code.





17.2.3 Material test certificates (physical properties, chemical composition & heat treatment report)

of the pressure containing parts shall be furnished for the valves supplied. Material test

certificates for the other parts shall also be furnished for verification during inspection.

17.2.4 Catalogues / Drawings (6 sets) shall be furnished along with delivery for Purchaser’s /

Owner’s record for all types of valves.

18 Guarantee

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

18 months from the date of receipt or 12 months from the date of commissioning whichever

is earlier against the medium as listed in individual technical specification and the service

condition specified in the Pipe Specification Index enclosed.

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

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

sheets.

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





Annexure I: Gate & Globe Valves

1 General

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

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

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

1.2 Steel Globe Valves shall conform to the following standards:

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

BS 1873 for sizes 2" and larger.

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

acceptable without prior approval.

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

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

1.6 By-pass

1.6.1 By-pass requirement for gate valves shall be provided as per the following.

Basic design of by-pass shall be as per MSS-SP-45 and ASME B 16.34.

ASME 150# On sizes 26” and above




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

On main valve up to 4” = 1/2” or more

On main valve 6” to 8” = 3/4” or more

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

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

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

main valve body shall not be screwed. All the fillet welds for by-pass installation shall be

100% examined by DP / MP test. All butt-weld joints shall be 100% examined by radiography.

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

pass assembly shall be the minimum possible for the layout reasons.

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

casting but not vice-versa.

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

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

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

seal welded.

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

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





1.14 All Gate / Globe valves shall have solid wedge for sizes 11/2” and below and flexible wedge

for sizes 2” and above.

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

maximum differential pressure for which the valve is designed, shall be supplied with a gear

operator, even if not specified in the purchase description.

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

fitted with a grease nipple.

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

hardness lower than the body and bonnet.

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

welded bonnets shall be 0.25% maximum.

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

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

stem horizontal, vertical, and inclined etc.

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

1.22 All valve body castings shall be of radiographic quality to ASME B16.34 APPENDIX-I and

shall be governed by the non-destructive testing requirements as per APPENDIX –II,III & IV

of ASME B16.34.

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

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

2 Identification Marking Requirements

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

relevant material certificate.

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

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

the gland studs with stainless steel wire of a minimum diameter of 1 mm, additionally the

Stock Code number shall be hard stamped on the bonnet flange rim in 3 mm high characters

minimum.

3 Testing

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

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

dried before despatch.

4 Certification

4.1 Material Certificates in accordance with EN 10204:3.1 are required for Bodies and Bonnets

and as a minimum shall include,

a) Chemical Analysis by Product

b) Mechanical Properties

c) Heat Treatment Statement

d) Non Destructive Test results

e) Hydrostatic and/or Pneumatic Test results

f) Heat or Melt Number





g) Dimensional check report.

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

certificates shall be from original forge or foundry. Certificates shall include the Owner /

Consultant’s purchase order number and purchase order item number.





Annexure II: Check Valves

1 General

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

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

BS 1868 for Swing Check Valves 2" and larger.

API 594 for Wafer Check Valves.

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

1500# & 2500# rating) shall have a drain boss. A tapped drain hole with plug shall be provided

as per ASME B16.34. Threads shall be as per ASME B1.20.1 (Taper) NPT. The drain boss

shall be provided at location ’Q’ in accordance with Fig.no.1 of ASME B16.34.

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

shall be ascertained.

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

of valve disc.

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

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

lugs, eyebolts and other such standard devices.

1.5 Piston lift check valves shall be installed only in horizontal lines. Swing type check valves

shall not be installed in vertically downward flowing lines.

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

valve is not acceptable without prior approval.

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

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

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

Indian Standards.

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

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

ANSI B16.34.

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


shall be govern by the non-destructive testing requirements as per APPENDIX–II, III & IV of

ASME B16.34.


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




the Valve Body with stainless steel wire of a minimum diameter of 1 mm, additionally the

Stock Code number shall be hard stamped on the cover flange rim in 3 mm high characters

minimum.

3 Testing





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

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


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

specifications and shall be thoroughly dried.

4 Certification

4.1 Material Certificates in accordance with EN 10204:3.1 are required for Bodies and Covers and

as a minimum shall include,







g) Fire Safe Test Certificates

h) Dimensional check report.


certificates shall be from original forge or foundry. Certificates shall include the Owner /

Consultant’s purchase order number and purchase order item number.





Annexure III: Ball Valves

1 General

Steel Ball Valves shall conform to the following requirements:

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


1.2 All Ball valves shall be "Fire Safe" in accordance with either API 6FA, API 607 or BS EN

12266, Part-2 and have anti-static devices in accordance with BS EN ISO 17292. Fire safe

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

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

liners are not acceptable.

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

1.5 All ball valves shall be Bi-directional.

1.6 Ball shall be solid type unless otherwise specified.

1.7 Body seat shall be renewable type.

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

1.9 All Ball valves shall be supplied with position indicator.

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

150# 8” & smaller Floating ball

10” & larger Trunnion mounted

300# 4” & smaller Floating ball


600# & above 1.5” & smaller Floating ball


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

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

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

accordance with API 6D / ISO 17292.

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

limit stops.

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

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

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

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

whether a specific vent direction can be offered.

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

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

carbon steel and schedule 40S for stainless steel and of a material similar to the valve body.

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

hardness lower than the body and bonnet.





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

relevant test standards.

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


shall be governed by the non-destructive testing requirements as per APPENDIX –II,III & IV.

1.22 Ball valve cavities shall be vented to relieve excess pressure. Venting may be achieved through

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

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

permanently marked on the valve.

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

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

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

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

the proposed seat material which shall cover the class temperature pressure rating of the valve

and is superior to the seat/seal material specified in the valve datasheets.


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




the gland studs with stainless steel wire of a minimum diameter of 1 mm, additionally the

Stock Code number shall be hard stamped on the bonnet flange rim in 3 mm high characters

minimum.

3 Testing


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


4 Certification









g) Dimensional check report.


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

purchase order number and purchase order item number.





Annexure IV: Butterfly Valves

1 General

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

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

1.3 Valves shall be hydrotested in accordance with API 598.

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

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

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

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

specified in the purchase description.

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



shall be govern by the non-destructive testing requirements as per APPENDIX –II,III & IV.


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

the relevant material certificate.

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



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

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

3 Testing




4 Certification









g) Valve Serial Number













Annexure V: Plug Valves

1 General

1.1 Plug Valves shall conform to BS 5353.

1.2 The welding of flanges on to Valves to meet the requirements for a flanged end Valve is not


1.3 Glands shall be of a steel material.

1.4 Valve stem packing shall be adjustable by means of a bolted gland.

1.5 Lubricant sealant shall be suitable for the service & temperatures specified in valve

specifications.

1.6 Seals, diaphragms and gaskets shall be fire resistant and be suitable for the specified service &

temperatures.

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



shall be governed by the non-destructive testing requirements as per APPENDIX –II,III & IV.

2 Identification

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

the relevant material certificate.

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



the Valve Body with stainless steel wire of minimum diameter of 1 mm, additionally the

Stockcode number shall be hard stamped on the cover flange rim in 3 mm high characters

minimum.

3 Testing




4 Certification

4.1 Material Certificates in accordance with EN 10204:3.1 are required for Bodies and Covers and

as a minimum shall include,







g) Valve Serial Number






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







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

1 General

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

Order/Contract and shall be of radiographic quality.

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

production of consistently sound castings.

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

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

2 Casting Inspection Requirements

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

one for each size/ stockcode/ batch ,

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

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

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

whichever is higher, from each end.

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

casting weld repairs shall also have the weld deposit impact tested in accordance with

ASME B31.3 para. 323.3 at a temperature of minus 185 Degrees C (or lower), as part

of the welding procedure qualification.

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

a) Quality A

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

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

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

b) Quality B

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

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

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

c) Quality C

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

machined surfaces. For non-magnetic material, dye penetrant examination methods

shall be used (Clause 3.4).

d) Quality D

Visual examination in accordance with Clause 3.2.





Table 1

Type of Inspection

Sr

No

.

Material Rating

(LB) Quality B on

10% of quantity

of castings

Quality A on

10% of

quantity of

castings

Quality A on

100% of

quantity of

castings

150& 300 18” and above i

Carbon Steel and Low

Temp. Carbon Steel

ii Stainless Steel

(Other than those

mentioned above.)

Up to 600 Up to 16” 18” and above

3 Inspection Procedures And Acceptance Standards

3.1 Surface Preparation

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

3.2 Visual Examination

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

and other harmful effects.

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

3.3 Magnetic Particle Examination (MPE)

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

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

3.4 Dye Penetrant Examination (DPE)

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

procedure shall be in accordance with ASTM E16.5.

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

3.5 Radiographic Examination

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

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

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

of ASME B16.34.

Acceptance criteria : ASME B16.34, Annex B

3.6 Ultrasonic Examination

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

feasible.

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

Acceptance Level : ASTM A609





Quality level as follows:

Thickness Acceptance Level

< 50mm 1

50-100mm 2

> 100mm 3

4 Dimensions

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

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

5 Submittal of NDE Procedures

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

6 Repair Procedures

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

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

to the pressure boundary shall be by welding only.

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

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

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

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

The analysis of the deposited weld metal shall conform to the nominal analysis of the parent

casting.

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

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

for repairs to austenitic stainless steel where considered applicable for process or

environmental reasons.

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

Annexure VII: Pressure Testing Requirements

Table 1





Valve

Type

Hydrotest

Body

(1.5 x DP)

Hydrotest

Seat

(1.1 x DP)

Hydrotest

Backseat

(1.1 x DP)

Pneumatic Test

Seat

(7 bar)

Disc Strength

Test

(1.5 x DP)

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

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

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

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

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

& Larger

Parallel

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