2113-9755 spec for gate valves

7/28/2019 2113-9755 Spec for Gate Valves

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0 15.11.2004 ISSUED FOR TENDER

REV. DATE DESCRIPTION PREP. CHECK. APPR. APPR. APPR.

ENGINEERING DEPARTMENT

PROJECT / CONTRACT REF.:

ENGINEERING, PROCUREMENT, INSTALLATION AND COMMISSIONING

OF

FUEL GAS SUPPLY TO QNCCIII, DUKHAN

DOCUMENT TITLE :

SPECIFICATION FOR GATE VALVES

SCALE

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DATE

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CAD REF.

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DOCUMENT No. REV.

DWG/DOC NO. 2 1 1 3 9 7 5 5 SHT. 0 1 OF. 1 2 0


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DOC No. : CONTRACT No. Sheet Rev. 0

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TITLE : SPECIFICATION FOR GATE VALVES

CONTENTS

1.0 SCOPE

2.0 REFERENCE DOCUMENTS

3.0 MATERIALS

4.0 DESIGN AND FABRICATION

5.0 INSPECTION AND TESTS

6.0 TEST CERTIFICATES

7.0 PAINTING, MARKING AND SHIPMENT

8.0 SPARES AND ACCESSORIES

9.0 DOCUMENTATION

10.0 QUALITY ASSURANCE

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1.0 SCOPE

This Specification establishes the minimum requirements fordesign, manufacture, testing and supply of Carbon Steel GateValves of size DN 50 mm (2") to DN 400 mm (16), to be usedin piping systems handling wet sour gas and crude oil for Qatar

Petroleum (QP) Projects.

2.0 REFERENCE DOCUMENTS

2.1 All Gate Valves shall be manufactured and supplied inaccordance with the Design Code API 600, with additions andmodifications as indicated in this Specification.

2.2 Reference has also been made in this Specification to the latestedition of the following Codes, Standards and Specifications :

2.2.1 Codes and Standards:

a) API 600 - Steel Gate Valves - Flanged &Butt Welding Ends.

b) ASME B 31.8 - Gas Transmission & DistributionPiping Systems.

c) ASME B 31.3 - Chemical and Process PlantPiping Systems.

d) ASME B 16.5 - Steel Pipe Flanges and FlangedFittings.

e) ASME B 16.25 - Butt-welding Ends.

f) ASME B16.34 - Steel Valves.

g) API 1104 - Specification for Welding Pipelineand Related Facilities.

h) API RP 6FA - Specification for Fire SafeValves.

i) ASME Sec VIII Div I - Boiler and PressureVessel Code - Rules forConstruction of Pressure Vessels.

j) ASME Sec IX - Boiler and Pressure Vessel Code -Welding and BrazingQualification

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k) ASTM A 105 - Specification for Forgings,Carbon Steel for PipingComponents

l) ASTM A 216 - Specification for Carbon SteelCastings, Suitable for FusionWelding for High TemperatureService.

m) ASTM A 370 - Mechanical Testing of Steel

Products

n) MSS-SP-6 - Standard Finishes for ContactFaces of Pipe Flanges andConnecting-end Flanges ofValves and Fittings.

o) MSS-SP-44 - Steel Pipeline Flanges

p) MSS-SP-53 - Quality Standard for SteelCasting and Forgings for Valves,Flanges and Fittings and Other

Piping Components - MagneticParticle Examination Method

q) NACE MR-01-75 - Material Requirements - SulphideStress Cracking Resistance OfMetallic Materials for Oil FieldEquipment.

r) EN 10204 - Metallic Products - Type of Inspection Documents

s) ISO 9000 - 9004 - Quality Management and QualityAssurance Standards

2.2.2 QP Standards/Specifications:

a) QP-SPC-L-002 - Standard Specification forPainting &

Wrapping of Metal Surfaces.

b) QSP-QC-09 - Quality System Requirement forthe

Engineering Construction andPre-commissioning Phases of

Onshore and

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Offshore Projects.

2.3 Order Of Precedence

In case of conflict between the requirements of thisSpecification and the referenced Codes, Standards andSpecifications, the following order of precedence shall apply:

a) This Specification

b) Project Specifications

c) QP Standards/Specifications

d) Other International Codes and Standards

3.0 MATERIALS

3.1 Material for major components of the Valves shall be asindicated in the Valve Data Sheets. Other components shall beas per Manufacturer's Standard, which shall be subject to

approval by the Purchaser. The materials of construction shallbe suitable for the wet sour gas composition given inAttachment-I, herewith, and shall meet the requirements ofNACE MR-01-75. Acceptable material for the pressurecontaining parts shall be ASTM A105, ASTM A216, orequivalent. However material grades shall be as indicated inthe Procurement Documents. All internals shall be SS 316.

3.2 Carbon steel used for the manufacture of Valves shall be fullykilled.

3.3 In addition to the requirements of the material specifications,chemical composition of each heat of steel used, on productanalysis shall have a maximum Carbon content of 0.25%, amaximum Manganese content of 1.20% and a maximumSulphur content of 0.01% for forgings.

3.4 Valve end connections which are subject to further fieldwelding by the Purchaser shall have a Carbon Equivalent (CE)not exceeding 0.43 for each heat of steel used, based onproduct analysis, when calculated by the following formula:

CE = C +Mn

6+

Cr + Mo+V

5+

Ni + Cu

15

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3.5 Unless specified otherwise, the Charpy impact test shall beconducted as per API 6D, at -10C. The Charpy impact testspecimen shall be taken in the direction of principal grain flowand notched perpendicular to the original surface.

The minimum average absorbed energy per set of 3 specimensshall be 60 J with an individual minimum per specimen of 48 J.No specimen shall exhibit less than 80 percent shear area.

3.6 For all pressure containing parts of the Valve, a full thicknesscross section shall be taken for hardness test per heat of basemetal. The maximum hardness shall not exceed 248 HV10.

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3.7 All carbon steel castings and forgings shall be furnished eitherin the normalised, normalised & tempered or quenched &tempered condition. Austenitic steels shall be furnished in thesolution annealed condition. All heat treatment shall complywith the requirements of NACE MR-01-75.

3.8 Seal material shall be suitable for the service conditionsindicated in Attachment- I. Acceptable seal material shall beViton or equivalent. Packing material shall be inhibited Grafoilor equivalent.

4.0 DESIGN AND FABRICATION

4.1 TheValve design shall meet the requirements of API 600 andshall be suitable for the service conditions indicated in theProcurement Documents. The Valve body and other pressurecontaining parts shall be designed in compliance with ASMESection VIII, Division 1. The Corrosion allowance indicated inthe Valve Data Sheet shall be considered in the design.However the minimum wall thickness shall not be less than theminimum requirement of ASME B16.34.

4.2 The Cover shall be bolted to the body. Screwedconnections are not acceptable.

4.3 Valve design shall provide for the repair of gland packing under

full line pressure.4.4 Valve ends:

a) Valve ends shall be of the flanged type as indicated inthe Valve Data Sheet. Flanges shall be integrally castwith the body of the Valve. Face to face/end to enddimensions shall conform to the design codes.

b) Flanged ends shall have dimensions as per ASME B 16.5.Flange faces shall be raised with Smooth finish 125 to250 AARH.

4.5 The Valve stem shall be capable of withstanding themaximum operating torque requirement to operate the Valve

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against the maximum differential pressure as per theappropriate class. The combined stress shall not exceed themaximum allowable stresses specified in ASME Section VIII,Division 1. The design shall take into account a safety factor of1.5 based on the maximum output torque of the operatingmechanism.

4.6 Operating Devices

a) Valves of 4 N.B (DN 100), and below shall be manuallyoperated. Valves of 6" N.B (DN 150), and above, shall begear operated. Gear operators shall be sized such thattheir output torque is at least 1.5 times the maximumoperating torque of the Valve. The Valve design shall besuch, that damage due to malfunctioning of theOperator, or its controls, will only occur in the gear trainor power cylinder. Damaged parts should be able toreplaced without the Valve cover being removed.

b) The diameter of the hand wheel for manually operatedValves, shall be such that under the maximum differentialpressure, the torque required to operate the Valve doesnot exceed 350 Nm. The Manufacturer shall also indicatethe number of turns of the hand wheel required foroperating the Valve from the fully open to fully closedposition.

c) The Direction of operation of the hand wheel shall be in aclock-wise direction for closing the Valves. Hand wheelsshall not have protruding spokes.

d) Gear operators, where provided, shall have a self-lockingprovision and shall be fully encased in a waterproof/splash proof enclosure (IP65) and shall be filledwith suitable grease.

4.7 Repair by welding is not permitted for forged Valves.However repair by welding as per ASME B 16.34 is permittedfor cast Valves. Repairs shall be carried out before any heattreatment of the casting is done. Repair welding procedurequalifications shall include hardness tests and shall meet the

requirements of Clause 3.5 of this Specification. Repair weldingprocedures shall be established in such a manner that therequirements of NACE MR-01-75 are met without the necessityof post weld heat treatment.

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4.8 When specified in the Valve Data Sheet, Valves shallhave locking devices to lock the Valve either in a fully open(LO) or fully closed (LC) position.

4.9 When specified in the Valve Data Sheet, Gate Valvesshall be fire safe in accordance with API RP6FA, for whichqualifying certificates, covering the range of items offered,shall be supplied by the Manufacturer

4.10 All Valves and Gear Operators shall have a stainless steelName plate permanently affixed with stainless steel pan headscrews. Each Name plate shall have, as a minimum, thefollowing information stamped thereon:

Manufacturer

Year of Manufacture

Serial No.

Tag no

Sizetogether with all other data required by specification API 600

5.0 INSPECTION AND TESTS

5.1 Where called for in the Procurement Documents theManufacturer shall appoint a reputable Third Party InspectionAgency (i.e. BVQI, Lioyds and DNV), to carry out all inspectionand tests as per the requirements of this Specification and therelevant codes, at his Works , prior to shipment. The cost ofsuch Third Party Inspection shall be included in the TenderedSum; also, the Third Party Inspection Agency shall be approved

by the Purchaser prior to his appointment. Such inspection andtests shall be as a minimum, but not be limited to, the following:

5.1.1 Visual inspection

5.1.2 A Dimensional check on all Valves shall be carried out asper the drawings approved by the Purchaser.

5.1.3 Chemical composition and mechanical propertiesincluding hardness shall be checked as per relevant materialstandards and this Specification, for each heat of steel used.

5.1.4 a) Non-Destructive examination of individualValve material and components consisting of, but notlimited to, castings and forgings, shall be carried out bythe Manufacturer.

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b) Body castings of the Valves shall beradiographically examined on 100% of the surface ofcritical areas as per ASME B16.34. Procedure andacceptance criteria shall be as per ANSI B16.34. Allcastings shall be subject to wet magnetic particleinspection on 100% of their internal surfaces. Methodand acceptance shall be in accordance with MSS-SP-53.

c) All forgings shall be ultrasonically examined

in critical areas in accordance with the procedure andacceptance standard of Annexure- E of ASME B 16.34. Allforgings shall be subject to wet magnetic particleinspection on 100% of their forged surfaces. Method andacceptance shall be in accordance with MSS-SP-53.

5.1.5 a) Cast Valves subject to field welding shall be100% radiographically examined on their welding endsand acceptance criteria shall be as per ANSI B16.34.

b) All finished wrought welding ends subject tofield welding shall be ultrasonically tested on 100% of thewelded area for lamination type defects for a distance of50 mm from the end. Laminations more than 50mm shallnot be acceptable.

5.1.6 All the Valves shall be Hydrostatically tested incompliance with the requirements of API 600.

5.1.7 A supplementary Air Seat Test shall becarried out for all Valves with leakage criteria in accordancewith the Data Sheets.

5.1.8 Valves shall be subjected to an Operational Torque Testas per clause C4 of API Spec. 6D under hydraulic pressureequal to the maximum differential pressure corresponding tothe Valve rating. For manually operated Valves, it shall beestablished that the torque required to operate the Valve doesnot exceed 350 Nm.

5.2 The Purchaser also reserves the right to witness tests asindicated above at the Manufacturers works, prior to theshipment. The Manufacturer shall give reasonable access and

facilities required for inspection to the Purchasers Inspector.The Purchaser reserves the right to require additional testing,at any time, to conform or further investigate, a suspectedfault. The cost incurred shall be to the Manufacturers account.

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In no case shall any action of the Purchaser, or his Inspector,relieve the Manufacturer of his responsibility for material,design, quality or operation of the Valves. Inspection and testsperformed/witnessed by the Purchasers Inspector shall in noway relieve the Manufacturer of his obligation to perform therequired inspection and tests.

5.3 The Purchaser may, at his discretion appoint a ThirdParty Inspection Agency to carry out inspection on behalf of, or

together with, the Purchasers Inspector.

6.0 TEST CERTIFICATES

6.1 The Manufacturer shall submit the following Certificatesin accordance with EN 10204 3.1 C or 3.1.B, as specified in theProcurement documents:

a) Mill test certificates relevant to the chemical analysis andmechanical properties of the materials used for the Valveconstruction as per the relevant standards.

b) Report on any heat treatment carried out.

c) Test certificates for hydrostatic and pneumatic testscomplete with duration and pressure records of eachtest.

d) Test reports of radiography, ultrasonic, MPI and DPinspection.

e) Test report on operation of Valvesconforming to Clause 5.1.8 of this Specification.

f) Fire Safe type certificates, as appropriate.

g) All other test reports and certificates as required by API600 and this Specification.

6.2 The Certificates shall be valid only when signed by thePurchasers Inspector. Only those Valves which have beencertified by the Purchasers Inspector shall be dispatched fromthe Manufacturers works.

6.3 The Serial No. of each Valve shall provide a cross reference toall Documentation required in accordance with EN 10204.

7.0 PAINTING, MARKING AND SHIPMENT

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7.1 After all inspection and tests required have been carriedout, the external surface of the Valves shall be thoroughlycleaned, freed from rust & grease and painted in accordancewith QP Standard Specification for Painting and Wrapping ofMetallic Surfaces No. QP-SPC-L-002, final colour white.

7.2 All Valves shall be marked as per API 600, the units beingmetric.

7.3 Valve ends shall be suitably protected to avoid any

damage during transit. All threaded and machined surfacessubject to corrosion shall be well protected by a coat of greaseor other suitable material. All Valves shall be provided withsuitable protectors for flange faces, securely attached to theValves.

7.4 All sealant lines and other cavities of the Valve shall befilled with sealant before shipment.

7.5 Valves shall be carefully packed in crates or pallets sothat they can not impact on each other during transit. Painted

surfaces shall also be so protected.

7.6 Each individual crate shall be marked on top and at leastone side with the following:

Contract No. and Name

Consignees Name and Address

Purchasers Order No. and Item No

Description of goods

7.7 The Vendor will be entirely responsible for any claim

arising which is attributable to defective and/or insufficientpacking.

8.0 SPARES AND ACCESSORIES

8.1 TheManufacturer shall recommend and quote separatelythe spares for Valves required for commissioning and two yearsof normal operation.

8.2 The Manufacturer shall recommend accessories (i.e.wrench, sealant injector, etc.) and special tools required for

operation and maintenance of Valves for the Purchasersreview.

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8.3 The Manufacturer shall complete the QP Standard SpareParts Lists and Interchangeability Record (SPIR) attached to theProcurement Documents and submit with his Tender. Pricesshall also be included.

9.0 DOCUMENTATION

9.1 Upon placement of order, the Manufacturer shall submit,

as a minimum, but not limited to the following drawings,documents and specifications for Purchasers approval :

a) Assembly drawings with overall dimensions including allfeatures and Valve operator.

b) Detailed sectional drawings showing all partswith reference numbers and materials specification.

c) Heat Treatment, Welding, Inspection and TestingProcedures.

d) Details of the proposed Painting to QP Specification

QP-SPC-L-002.

e) Quality Control Manual and Quality Control Plan

f) Design calculations pertaining to Valve body and stemdesign.

Manufacture of Valves shall commence only afterapproval of the above documents. Once the written approvalhas been given by Purchaser, any changes in design, materialand method of manufacture shall be notified to the Purchaserwhose approval in writing of all changes shall be obtained

before the Valves are manufactured.

9.2 On receipt of written approval, the Manufacturer shallsubmit to the Purchaser all the approved drawings, documentsand specifications as listed in Clause 9.1 above.

9.3 Prior to shipment, manufacturer shall submit thefollowing to Purchaser:

a) Test certificates as listed in Clause 6.0 of thisSpecification.

b) A Manual for Installation, Maintenance and Operation ofthe Valves.

9.4 Documents shall be in the English language.

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10.0 QUALITY ASSURANCE

The Manufacturer shall operate a Quality Systemmeeting the requirements of the relevant Part of ISO 9000.Guidance for Vendor conformance requirements to ISO 9000 isgiven in QP Standard Specification No. QSP - QC - 09. TheManufacturer shall ensure that his sub-suppliers operate aQuality System meeting the specified conformance criteria to

ISO 9000. The Manufacturers Quality system shall be subjectto the Purchasers approval prior to commitment to thePurchase Order. Major sub-suppliers shall be subject toidentical approvals. The Purchaser reserves the right toconduct a Quality Audit at the Manufacturer(s)/sub-supplier(s)facilities at any stage during manufacture.

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