primary system valves - npcil e-tenders
TRANSCRIPT
PP-E-999
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PRIMARY SYSTEM VALVES
1.0 SCOPE
This specification, together with the associated valve specification sheets and drawings,
establishes the technical requirements for the design. Manufacture, inspection and testing of
valves for the primary Heat Transport System.
2.0 Contests Section
Applicable Documents 3
Publication 3.1
Drawings 3.2
Material & Workmanship 4
Requirements 5
General 5.1
Requirement for valves 5.2
General 5.2.1
Valve design 5.2.2
Earthquake loading 5.2.3
Valve bodies and bonnets 5.2.4
Valve trim 5.2.5
Valve stem sealing arrangement 5.2.6
Back seats 5.2.7
Diaphragm 5.2.8
Threaded fasteners 5.2.9
Valve position indicators 5.3
Interchangeability 5.4
Valve making & identification 5.5
Inspection & testing requirements. 5.6
Inspection Documentation requirements 5.6.1
Requirements for Pneumatic Operator 5.7
General 5.7.1
Pneumatic Piston operators 5.7.2
Pneumatic Diaphragm operators 5.7.3
Limit switches for valve position indication 5.7.4
Electric driven valve operators 5.8
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Valve operator assembly 5.9
Inspection & testing 6
General 6.1
Inspection or test failures 6.2
Material tests 6.3
Radiographic inspection 6.4
Magnetic particle & liquid Penetrate inspection. 6.5
Magnetic particle inspection 6.5.1
Liquid Penetrant Inspection 6.5.2
Ultrasonic inspection 6.6
Inspection and testing of bellows 6.7
Hydrostatic test 6.8
Helium leak test 6.9
Functional test 6.10
Examination of product 6.11
Cleanliness 6.12
Documentation 7.0
Preparation for shipment 8.0
Specific requirements. 9.0
Gate valves 9.1
Actuator for gate valves 9.1.1
Check valves 9.2
Butterfly valves 9.3
Actuator for butterfly valves 9.3.1
Plug/ball valves 9.4
Actuator for plug /ball valves 9.4.1
Requirements of extensions fitted to the valve Annexure-I
3.0 Applicable Documents :
All documents listed below, of the issue in effect on the date of the pertinent tendering documents
constitute a part of this specification to the extent defined subsequently in the specification.
3.1 Publications :
ANSI B.1.1 Unified Screw Thread.
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ANSI B 2.1 Pipe threads (except dry seal)
ANSI B16.5 Steel pipe flanges and flanged fittings.
ANSI B16.10 Face to face and end to end dimensions
of ferrous valves.
ANSI B16.11 Forged steel fittings for socket welding
& threads.
ANSI B16.25 Butt welding ends.
ANSI B16.34 Steel valves, flanged and butt welding
ends.
ANSI B16.41 Functional qualification requirements for
power operated active valve assemblies for nuclear power plants.
ASME Boiler & Pressure Vessel Code section
II,III,V and IX.
ASTM Appropriate publications for materials.
MSS-SP-25 Standard marking system for valves
fitting, flanges and unions.
PP-E-465 Motor Driven valve operator.
IEEE-382 IEEE Standard for qualification of safety related valve actuators.
In case contractor refers to any other standards. These shall be equal to or better than the
standards listed above. Use of such standards shall be subject to approval by the purchaser.
In the event of any conflict between the requirement of this specification and the document listed
above, this specification shall govern.
3.2 DRAWINGS
EDG-B1 sheet no. 38 – Butt welding ends preparation for consumable inserts.
4.0 MATERIALS & WORKMANSHIP
Materials and standard parts which are not specifically designated herein shall be of good quality
and in accordance with the best practice in the manufacture of valves and operators.
Workmanship shall be in accordance with the best practice adequate to ensure satisfactory
operation, service life and ease of maintenance in accordance with the requirements of this
specification.
5.0 REQUIREMENTS
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General
This specification covers a variety of types and sizes of valves and operators. The specific
requirements and service conditions for each application are defined in the
respective valve
specification sheets which accompany this specification.
The requirements for valves are given in section 5.2
Requirement for operators are given in section 5.7 & 5.8.
The requirements for testing and inspection of valves, operators and assemblies are given in
section 5.6.
The design and construction of the valves and operators shall be appropriate for very long life and
trouble free plant service for the condition listed on the pertinent valve specification sheets.
Most of the equipment included in this specification is located in normally inaccessible areas.
Ambient temperature will not exceed 66 deg. C. All components of valves and operators other
than consumable items shall be suitable for operation in radiation fields of the intensity of 200 R/h
for a period of 30 years. Consumable items shall withstand in the specified intensity for at least 2
years. Any such items shall be defined by the contractor and the use of such shall be subject to the
approval of purchaser.
5.2 REQUIREMENTS FOR VALVES :
5.2.1 General
Valves intended for heavy water service will handle high purity, oxygen-free heavy water with a
PH maintained in the range of 9.5 to 10.5 by the addition of lithium hydroxide. Valves intended
for fluids or gases other than heavy water will handle fluids or gases listed on the valve
specification sheets.
All materials shall be selected by the contractor to appropriate ASTM or equivalent specifications
except that proprietary materials may be used for special items such a valve trim, subject to
approval by purchasers. Material requirements are described fully in subsequent sections dealing
with various parts of the vales.
5.2.2 Valve Design
The design of valve shall conform to ASME section-III class NB with additional requirements of
this specification and respective valve specifications sheets, the component design classification
and specific requirements are indicated on individual valve specification sheets.
5.2.3 Design to withstand earthquake load
Unless otherwise specified in the respective valve specification sheet all valves and valve operator
assemblies are required to with stand following design basis earthquake, which may arise from the
local seismic conditions given below.
i) Safe Shutdown Earthquake (SSE)
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2.0 g each in two horizontal orthogonal directions concurrently along with 1.5 g in vertical
direction (to be considered for service limit „Level C‟)
ii) Operating Basis Earthquake (OBE)
The loads are half of SSE ( to be considered for service limit
„Level B‟)
Design of valve operator assembly shall be such that first natural frequency is above 33
Hz. In case, the same is less than 33 Hz. Then operability of valve under seismic loading
shall be demonstrated using shake table. First natural frequency of valve operator
assembly shall be determined as per ANSI B16.41.
5.2.4 Valve Bodies & Bonnets :
The rating shall be as specified on the appropriate valve specification sheet and shall be in
accordance with the pressure rating classification of ANSI-B-16.34 and thickness shall conform to
the requirements of NB-3542 of ASME code section III.
The end-to-end dimensions of valves shall be equal to those defined in ANSI B 16.10.
Where butt welding ends are specified, the weld preparation shall be in accordance with
purchaser‟s drawing EDG-B-1 sheet no 38. It is brought to the attention of the contractor that the
tolerance on nominal I.D including quality at the end preparation shall be 0.8 mm. The width of
the land shall be 1.6mm in addition, the squareness of the weld preparation shall be such that no
point on the land of the preparation shall deviate more than 0.508 mm from a plane perpendicular
to the axis of the run of the valve. Sharp re-entrant angles on valve extensions or inlet and outlet
connections shall not be permitted.
Where a flanged end valve is specified, the diameter and drilling shall be in accordance with
ANSI B16.5. The facing shall be as specified on the valve specification sheet. Surface finish shall
be suitable for using spiral wound type gasket. Where threaded ends are specified, the
preparations shall be in accordance with ANSI B2.1.
The following materials are considered suitable by purchaser for valve bodies, bonnets and other
pressure retaining parts.
a. Valve bodies, bonnets, discs, seat ring etc.
Carbon steel : SA 350 LF2 or SA352 LCB
Stainless steel : SA-182 F304L or SA 351 CF3.
b. Stem : SA 564 Gr 630
c. Penetrating pipes :
Carbon steel SA333 Gr.6
Stainless steel SA376 TP304L.
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Any welds in pressure containing parts of the valve, or extensions thereto, other than repair welds
in castings and seal welds shall be full penetration butt welds. All welds and seal welds shall be
performed in accordance with the requirements of article NB-4300 of ASME boiler and pressure
Vessel code section-III. Reference in particular shall be made to NB-4100, NB-4231, NB-4300
(NB 4350 and NB-4360 not applicable) and NB 4400 with the following additional requirements
and deviations.
a. Reference to inspection procedures shall be supplemented by those specified in section 6
herein.
b. Maximum off set values given in NB 4232 shall not apply. The maximum radial off set at the
inner surfaces of butt welds shall not exceed 0.8 mm as shown on purchaser‟s drawings EDG-
B-1 sheet no 38..
Weld repair of castings and forgings shall be carried out in accordance with the requirements of
NB-2570 and NB-2540 respectively.
The closure at the joint between the body and the bonnet or other similar openings shall be one of
the following.
a. Pressure seal type
b. Bolted type with metallic gaskets ( ring joint retained spiral wound gaskets or similar types)
c. Threaded joints with seal welds.
d. Bolted flanges for diaphragm type valves.
Any special requirements, such as double proposed and inter gasket leak off shall be as listed on
the valve specification sheets.
The tender shall clearly describe the proposed method of closure. Alternatives to those listed
above shall be subject to the approval of purchaser.
The finish on all un-machined internal and external surfaces shall be 10 micron RMS or better,
surface finish under spiral wound type gaskets shall be 3.2 micron RMS or better.
5.2.5 Valve Trim
The design and materials for the valve trim shall provide maximum resistance against the effect of
corrosion, erosion, galling and leakage.
Valve seats ( including backseats ), plug, discs and gates shall be hard faced. The materials used
for hard facing shall be free from cobalt and subject to approval by purchaser. Hard facing shall
meet the requirements of ASME- Section-IX.
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The stem shall be heat treated suitability to have required hardness and impact properties. The
surface finish on the stem shall be 0.8 micron RMS or better.
The materials used for the bellows in bellows sealed valves shall be inconel 600 or Nimonic 75 or
other suitable materials. Alternative materials shall be subject to approval of purchaser.
The materials for other trim components shall be selected by the contractor for the particular
service conditions shown on the valve specification sheets.
Where a special plug form is required, this is shown on the appropriate valve specification sheet.
5.2.6 Valve stem sealing Arrangements :
The method of valve sealing shall be as defined on the valve specification sheet and will be either
:
a) Bellows seal with a single back up gland packing (Without leak off connection) or
b) Double packed gland with lantern ring leak-off connection between pickings.
The bellows used in bellows sealed valves shall be compatible with the operating conditions
stated on the valve specification sheets. The bellows shall be guaranteed for a minimum cycle
life of ten thousand (10,000) full stem travel operations at the stated maximum service
conditions. One cycle is fully open to fully close to fully open.
The requirements for inspections and testing of the bellows are defined in section 6.
For all bellows sealed valves a single packing back up gland shall be provided, this back-up gland
shall be capable of sealing against the maximum service conditions stated on the valve
specifications sheets. The packing materials shall be as defined in this section.
Double gland packing when specified, shall consist of an inner packing separated from the outer
packing by means of a spacer or lantern ring.
The inner packing and the outer packing shall separately be capable of sealing against maximum
service pressure.
The single 10mm (3/8 inch) NPT tapped hole shall be provided to the lantern ring leak off
cavity. Alternative leak-off connection arrangement are subject to the approval of purchaser.
The lantern rings shall have two blind holes drilled and tapped for 8-32 screws. These holes shall
be located in the top face 180 degree apart. If split rings are used each half shall have two such
holes, 90 degrees apart. These holes will accommodate a tool for removal of the lantern ring.
For all valves the stem gland packing shall be high density grafoil or a combination of
grafoil & graphitised asbestos.
For hand operated diaphragm valves, bonnet shall be either indicating or non indicating type
stem. In indicating type a closure cap should be used to fill the stem opening in the hand
wheel. In the case of non indicating type bonnet adjustable travel stop shall be
provided to limit stem travel for avoiding over compression of diaphragm on the body
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weir. The indicating stem shall be provided with stop but & lock nut. Bonnet shall have
no packing gland and be sealed with EPDM o-ring. Positive support of diaphragm to protect
from ballooning against high line pressure and pressure surges shall be provided by alternate
fingers of compressor and finger plate in valves sizes up to 50 NB and by fingers cast with the
bonnet in larger sizes. Bonnet shall be provided with V-notch plug for checking diaphragm
integrity without disassembling. The plug shall have tapered pipe threads.
5.2.7 Back Seats
Unless otherwise stated on the valves specification sheets, all valves other than bellows sealed
valves, shall be provided with back seats.
5.2.8 Diaphragm
The material for diaphragm shall be as specified in the individual valve specification sheet
Diaphragm and O-ring seals shall have a minimum design life of 20,000 cycles, Diaphragm shall
have strong adherence to the reinforcing fabric and the stud head.
5.2.9 Threaded Fasteners
The materials used for all pressure bearing threaded fasteners shall conform to SA 540 B24
class.4.
All threads shall be unified series screws threads and shall conform to ANSI B1.1. All
threaded pressure retaining fasteners shall be provided with corrosion resistant positive locking
devices, frictional locking devices are not acceptable.
5.3 VALVE POSITION INDICATORS
All valves, other than rising spindle types, shall be provided with a valve position indicator
marked to show open and shut position. For valves with operators the position indicator may be
provided on the operator.
5.4 INTERCHANGEABILITY
Components and spare parts of valves and operators shall be interchangeable among valves of one
size and elsewhere to the maximum practical extent.
5.5 VALVE MARKING AND IDENTIFICATION
The valve bodies and attached parts shall be marked with the information called for in MSS-SP-
25.
The Purchaser shall provide an identification tag for each valve. The contractor shall securily
attached this identification tag to the valve with corrosion resistant wire.
If any operator is packed or shipped disassembled from the valve the contractor shall tag the
operator with the same purchaser‟s identification number as the valve.
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5.6 INSPECTION & TESTING REQUIREMENTS
The materials, components and completed valve assembles shall be inspected and tested as
defined below.
The inspection and testing of all materials and components of the valves is listed in Table I of this
specification. Detailed inspection and testing requirements, as well as acceptance levels, are given
in section 6 hereof.
In addition to the requirements for inspection and testing of the bellows as defined in Table I, the
requirements of section 6.7 shall be carried out.
The completed valve shall be subject to the hydrostatic shell, seat and back seat tests as
described in section 6.8. Following the hydrostatic tests, a helium leak test shall be
performed in accordance with section 6.9 of this specification.
When required by the valve specification sheet, an air leak seat test shall performed. Inspection
and test requirements for pneumatic operators shall be performed in accordance with section 5.7
of this specification.
Inspection and test requirements for electric operators shall be performed in accordance with
purchaser‟s specification PP-E-465.
TABLE-I
APPLICABLE SECTION OF SPECIFICATION
Item or Component Material
Tests
Radiography Ultrasonic Liquid Penetrant or
magnetic particle
Bodies : Castings
Forgings
6.3
6.3
6.4
No Reqd.
No Reqd.
6.6
6.5
6.5
Bonnets : Castings
Forgings
6.3
6.3
6.4
Not Reqd.
Not Reqd.
6.6
6.5
6.5
Pressure bearing: Castings /
Lugs Cover : forgings
6.3
6.3
6.4
No Reqd.
No Reqd.
6.6
6.5
6.5
Discs and Wedges: Castings
: Forgings
6.3
6.3
6.4
No Reqd.
No Reqd.
6.6
6.5
6.5
Stems and hanger pins 6.3
No Reqd.
6.6
6.5
Seat : Integral
Non –Integral
Not Reqd.
6.3
No Reqd.
No Reqd.
No Reqd.
6.6
6.5
6.5
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TABLE-I
APPLICABLE SECTION OF SPECIFICATION
Item or
component
Material Tests Radiography Ultrasonic Liquid Penetrant or magnetic
particle.
Nuts 6.3 Not Required 6.6 6.5
Bolts and studs 6.3 Not required 6.6 6.5
Bellows
assembly
6.3 6.4 Not required 6.5
Full penetration
welds
Not applicable 6.4 Not required 6.5
Note : Other items not listed ( Such as hand wheels, cotter pins etc) shall be to the manufacture‟s
standards.
5.6.1 Inspection Documentation Requirements
To complete the requirements of the inspection and testing procedure for the various components
as defined in table I. Section 5.6 the contractor shall submit the following documentation to the
purchaser.
a) Mill Test reports of chemical analysis and physical properties. Reports for castings shall
be identified with the heat and item number of the particular casting.
b) Copies of Radiography, ultrasonic and other non-destructive examination report and
casting defect chart or drawings identifying defect locations. These reports shall also be
identified with the item number of the particular casting.
c) A copy of welding operator and welding procedure records of qualification.
d) Reports of heat treatment including furnace charts and for castings, identification of the
item number of the particular component.
e) Test repots for each valve of hydrostatic, helium leak and air leak tests.
f) Performance test, Qualification report and other relevant test report.
5.7 REQUIREMENTS FOR PNEUMATIC OPERATORS :
5.7.1 General
All operators shall be suitable for long life in an environment of 66 deg. C. The arrangement of
the valve and operator shall be suitable to handle at the temperature specified on the valve
specification sheets.
The main air supply is clean, oil free dry air (-40 deg. C dew point). The supply air pressure for
each valve is stated on the valve specification sheets. The design and selection of individual
operator shall be such as to ensure.
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a. For spring and diaphragm or spring and piston types.
1. That the valve will fully stroke with a pressure of no more that 80% of the supply
pressure. In the direction requiring increasing pressure and.
2. That the valve will fully stroke with a pressure of not less than 15% of supply
pressure, in the direction requiring decreasing pressure.
b. For double acting types; that the valve will fully stroke in both direction with a differential
pressure across the operator of not more that 65% of the supply pressure.
c. For valves supplied with positioners, the requirements of „a‟ and „b‟ above shall be met without
being limited by the positioners.
Notwithstanding the foregoing, the intent is to provide operators as small and compact as
possible. Preference will be given to operators that utilize the highest air pressure.
All pneumatic operators shall be adequate to withstand the full supply air pressure.
All operators shall be sized to open or close the valve with a differential pressure across
the valve equal to the specified maximum pressure at inlet unless stated otherwise on the
valve specification sheets. The contractor shall state the actual operator pressures required
for each valve on the pertinent valve drawing, submitted as required for approved by the
purchaser.
The operator action shall be as indicated on the valve specification sheet ( air-to-open, air-
to close, or double acting). Within this limitation the pneumatic operator may be spring
and diaphragm, spring and piston, or double acting piston whichever is the most suitable
for the specified conditions.
When indicated on the valve specification sheet, the contractor shall supply a suitable
filter and / or pressure regulator to suit the air pressure selected or specified for the
operator.
A stem travel indicator with open and closed indication shall be provided on each
pneumatic operator.
The valve stem extension and / or the push rod from the operator shall be guided or
otherwise fixed to prevent rotation.
Each diaphragm operator and piston shall have provision for mounting solenoid pilot
valve. This shall consist of two suitable holes in the operator frame or yoke to which a
bracket with the solenoid valve may be attached using 6 mm bolts. Holes may be 30mm
clear to permit bolts to pass through or tapped to receive 6 mm (1/4 inch ) NC-20 threads.
The bolts, brackets, and solenoid pilot valve are not a part of this specification.
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Valve with pneumatic operators shall not be provided with hand wheel for manual
operation unless specified on the valve specification sheets.
Pneumatic operator shall be qualified as per IEEE-382 requirements. If operators are type
tested to other equivalent specifications full details of specification and test report shall be
furnished.
5.7.2 Pneumatic Piston Operators:
Pneumatic piston operators shall conform to all the general requirements of Section 5.7.1 above.
Where pneumatic piston operators are specified the actuator shall consist of a honed cylinder and
piston assembly. Operators shall be provided with self lubricated piston rings and stems seal. The
piston shall be adequately supported to provided direct linear-motion.
Where a supply failure position is indicated on the valve specification sheet, a loading spring shall
be provided. The length of the cylinder shall not be excessively greater than that required to
satisfy the stroke requirements.
The design of the operator and / or the main seat (s) and back seat if such exists shall be adequate
to withstand the impact load which may occur under the maximum velocity of the valve stem
resulting from the maximum accelerating force available.
5.7.3 Pneumatic Diaphragm operators
Pneumatic diaphragm operators shall conform to all the general requirements of section 5.7.1
above.
Diaphragm material shall be subject to approval by the purchaser.
5.7.4 Limit switches for valve position indication
When called for on the valve specification sheet, adjustment limit switch contact shall be provided
as follows.
1- Form C contact to actuate in the region of the closed position contact actuation to be
adjustable from full closed to at least half open.
2- Form C contact to actuate in the region of the open position contact actuation to the
adjustable from fully open to at least half closed.
The above limit switches shall be suitable for 1 amperes (Resistive ) at 240 volt AC and 48
volt DC. Switches shall be enclosed in weather proof NEMA 3 enclosures.
The mounting of the limit switches or of the limit switch actuating mechanism shall be
such as to permit smooth continuous adjustment and the exact fixing of the switch
actuating point. The design of the actuating mechanism shall permit the use of calibration
blocks to confirm actuating points by a “GO”, “No GO”, test and to confirm the adequacy
of switch over travel without moving the valve.
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5.8 Electric Motor Driven operators
The operators shall conform to purchaser specification PP-E-465 “Motor Drive valve operators :
except that each operator or valve shall be equipped with a stem travel indicator with open and
closed indications. The operator shall be qualified as per IEEE 382 requirements.
5.9 Valve operator assembly
Valve operator assembly shall be qualified as per the requirements of ANSI B-16.41. In case the
same is already qualified to another specification full details of specification along with test report
shall be furnished.
6.0 INSPECTION AND TESTING
6.1 General
Inspection and testing requirements for valve materials, valve components and completed valves
are defined in section 5 of this specification. The contractor shall be responsible for and shall
provide for and perform all the inspection and testing herein. Inspection and testing shall be
conducted in a manner satisfactory to and shall be subject to approval by the purchaser.
The purchaser and his authorized agencies shall have access to the contractor‟s premises at all
reasonable times to the extent necessary to assess compliance with the provisions of this
specification. The purchaser shall also have the right to conduct at his own expense any additional
inspection or testing he deems necessary.
6.2 Inspection or test Failure
In the event of failure of the valve or any part thereof to meet fully any inspection or test
requirements specified herein, the contractor shall obtain permission from
purchaser before repair or subsequent use of such equipment of part. If
the repairs including redesign are likely to affect the results of tests or work previously completed,
appropriate re-inspection and retesting shall be conducted.
Permission from purchaser is not required to perform weld repair on castings. However a report
shall be made on casting repairs describing the location and extent of repairs to each casting.
6.3 Material Tests
All materials designated as in accordance with an SA specification and shall be subject to all mill
test of chemical and physical properties required by the appropriate SA specifications.
In addition to these, the following tests and inspections (Listed in Table-1 of
section 5.6) shall be performed and the materials shall meet the stated
requirements.
Proof in the form of certified test reports or mill certificates that the required tests have been
carried out at the source will be acceptable, but if these are not available, the tests shall be
performed by the contractor.
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a. Ladle analysis for carbon steel castings shall include residual elements.
b. Check analysis from each heat or portion there of.
c. Impact tests shall be performed as per sub article NB-2300 of section III of the ASME
code and material specification and shall meet the impact values given therein.
d. Hardness test of each heat treated batch of material. Reports shall be submitted in
accordance with section 5.6.
6.4 Radiographic Inspection
a. Castings and weld Repairs to Castings
All pressure containing castings including wedges or discs when cast and weld repairs to
castings shall be completely (i.e 100%) Radiographed by methods in accordance with
paragraph NB 2570 of ASME section III and shall meet requirements thereof.
b. Full Penetration welds :
All fabrication welds joining pressure containing parts of valves, or welds of any
extensions thereto, shall be completely radiographed. Radiography shall be in accordance
with the procedure and shall meet the acceptance standards of article NB-5000 of Section-
III of the ASME boiler and pressure vessel code. In addition root and final pass of weld
shall be liquid penetrant or magnetic particle examined.
c. Bellows Longitudinal seam
Prior to forming the convolutions, the longitudinal seam weld shall be Radiographed by
procedure which will ensures sufficient sensitivity and contrast to clearly indicate the level
of defects described below. This procedure shall be approved by purchaser.
Sections of the weld that are shown by radiography to have any one of the following types
of defects are unacceptable.
i) Any type of crack or zone of incomplete fusion or penetration.
ii) Any other indications hereafter called sports. (porosity or inclusions ) exceeding 4
spots in any 25 mm of weld No spot shall have a dimension in any direction
exceeding 10% of the wall thickness of the bellows. The distance between
successive spots shall exceed 6L where L is the length of the longest spot.
6.5 Magnetic particle and liquid penetrant inspection
At some time prior to assembly the following the components shall be subjected to magnetic
particle or liquid penetrant inspection.
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a. All external and accessible internal surfaces of the pressure bearing parts of the body and
bonnet (where these surfaces have been previously inspected by the manufacturer of the
castings or forgings, such inspection need not be repeated except in areas which have been
subsequently machined. Bellows are not subject to magnetic particle or liquid penetrant
inspection except at welds.
b. The complete surface area of valve discs or gates including the facings.
c. The complete surface area of the stem.
d. Hard surfaces of back seats.
e. All pressure retaining studs, bolts, and nuts ( the examination shall be performed after
threading)
f. Final surfaces of all welds (this includes full penetration welds as well as fillet and seal
welds)
6.5.1 Magnetic Particular inspection
Magnetic particle inspection shall be performed in accordance with the procedure specified in
respective articles section III of the ASME code. With the following addition and modifications.
a. Surface shall be prepared for inspection by removal of all scale (not just loose scale) scale
shall be removed by a method which will not obscure defects.
b. The component shall be thoroughly cleaned on completion of inspection.
c. Demagnetization is required immediately following inspection.
d. The acceptance standard shall be :
i) Bolts, studs and nuts shall meet the requirements of NB 2580 of section III of the
ASME code.
ii) Valve seats (including back seats ) and valve steams shall be defect free.
iii) Forgings and castings shall meet the acceptance standard of para NB 2545 of
ASME code section III.
iv) Weld and all remaining components shall meet the requirements of NB-5340
section III of the ASME code.
6.5.2 Liquid penetrant inspection
Liquid penetrant inspection shall be performed in accordance with the procedure specified in
respective article of section III of the ASME code, with the following additions and modification.
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a. Penetrants, developers and cleaning agents shall preferably be halogen free but in no case
shall the halogen content exceed 25 parts per million. The penetrent shall be approved by
purchaser.
b. All traces of penetrant and developer shall be removed from the work on completion of
inspection.
c. The acceptance standards shall be
i) Bolts, studs and nuts shall meet the requirements of NB 2580 of section III of the
ASME code.
ii) Valve seats (including back seats ) and valve stems shall be defect free.
iii) Forgings & castings shall meet the acceptance standard of para NB 2546 of ASME
code section III.
iv) Welds and all remaining components shall meet the requirements of NB-5350 of
section III of the ASME code.
6.6 Ultrasonic Examination
All pressure retaining parts and all sizes of stem and back seat made of forgings and also pressure
retaining casting areas where readiography do not give meaningful result shall be ultrasonically
examined as follows.
a. Forgings shall be examined to meet all the requirements of NB 2540 of ASME section III
NB.
b. Castings shall be examined to meet all the requirements of NB 2570 of ASME section III.
c. Bolts, studs & nuts shall be examined to meet all the requirements of NB 2580 of ASME
section III.
6.7 Inspection & Testing of bellows
In addition to the inspection and testing requirements stated in table I, Section 5.6 of this
specification, the followings inspection and testing shall be carried out.
a. Following the forming of the convolutions each bellows shall be subjected to a hydrostatic
test. The test pressure shall not be less than 1.1/2 times the maximum pressure indicated for
service conditions on the valve specification sheet, and shall be maintained for a minimum
period of 5 minute. Any leakage and permanent deformation shall be cause for a rejection.
b. The completed bellows assembly shall be subjected to helium leak test as described in section
6.9.
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c. A minimum of two complete bellows assemblies from each production group shall be cycled
to failure at the pressure and temperature conditions stated on the valve specification sheet to
demonstrate conformity with the guaranteed minimum cycle life required.
The inspection and testing procedures shall be subjected to the approval of purchaser.
6.8 Hydrostatic Test
A hydrostatic shell test and seat test (including back seat test ) shall be carried out on each valve
in accordance with the requirements of ANSI B 16.34 except that the duration of any test shall not
be less than 10 minutes. The leakage through seat shall not exceed 5 ml per hour per inch of
nominal diameter.
When specified on the individual valve specification sheet an air leak seat test shall be performed.
The air test shall be carried out in accordance with and shall meet the requirements of MSS-SP-
61.
During the hydrostatic testing of the shell, the inner and outer gland packing shall be tested
separately to a certain the effectiveness of gland sealing arrangement. The packing shall be tested
as follows and shall meet the requirements stated here in :
For testing the inner packing back seat, if provided, shall be removed from contact and full
hydrostatic shell test pressure shall be applied on the packing. The plug shall be positioned at mid
stroke. The leak off the connection shall be checked and no leakage past the inner packing shall
be permitted. To test outer packing, the leak off connection between inner and outer packing shall
be pressurized to maximum service pressure stated on the respective valve specification sheet.
There shall be no leakage past the outer packing. Testing time for inner and outer packing shall be
5 minutes minimum.
Back seat shall be tested after removing gland packing and the stem back seated. The leakage
shall not exceed 10 cc/hr. at a pressure of not less than pressure rating of the valve at 38 deg. C.
Power operated valves shall be operated 5-6 times under full design pressure prior to seat leakage
test. At the maximum rated service pressure (unless otherwise stated in the respective valve
specification sheet) leakage rate shall not exceed 5 cc. Per hour inch nominal valve size. During
the test performance of operator meeting the requirement of para 5.7 shall also be demonstrated.
For check valves in addition hydrostatic seat leakage test as above a seat leakage test at 25% of
maximum rated service pressure as stated in the valve specification sheet shall be carried out.
Leakage rate shall not exceed 20 cc per hour per inch of nominal valve size.
In case of plug/ball and butterfly valve hydrostatic leakage test shall be carried out at a pressure as
indicated in ANSI B 16.34 No leakage is permitted.
Diaphragm valve body and bonnet castings shall be tested after machining to the hydrostatic shell
test pressure of 30 kg/cm2 (g) for 10 minutes. Hydrostatic body test shall be performed in full
open position of assembled valve at a pressure of 21 kg/cm2 (g) for 10 minutes. Before the test air
shall be evaluated from the valve all bonnet bolts shall be tightened until all leakage around
bonnet flange stopped. In addition V-notch plug shall be removed to check for leakage.
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Body & nozzle for safety relief valve shall be hydrostatic tested at a pressure not less than 1.5
times of respective flange rated pressure at 38o C. seat leakage test shall be carried out air at 90%
of set pressure. No leakage is allowed.
6.9 Helium leak Test
Subsequent to hydrostatic test, helium leak test shall be carried out in fully assembled valve.
Prior to helium leak test the valve body shall be thoroughly dried. Fully assembled valve shall be
tested using hood method in accordance with article T-1060 of ASME section-V. Leakage rate
shall not exceed 10-6 Std m1/sec. in case of double gasketted body bonnet joint. Inner gasket joint
shall be tested by pressuring valve with helium gas containing at least 50% helium at 1 kg/cm2 (g)
and leak shall be detected through inter gasket leak off connection. Outer gasket joint shall be
tested by pressuring inter gasket space as above with helium. Leak shall be detected from out side.
Leakage through un-wetted gasketted joints shall not exceed 10-4 std m1 / sec. Details of helium
leak test shall be subjected to purchaser approval.
6.10 Functional test
All manual and power operated valve shall be subject to operation tests at the designed service
pressure as specified in the respective valve specification sheet. Power operated valve shall be
fully calibrated including setting of limit/torque switches, mechanical stop position indicating
switches before functional testing valves shall be operated under adverse condition.
6.11 Examination of Product
The complete valve shall be examined to determine its conformance with this specification with
respect to material, workmanship, finish, markings and dimensions and to assess its conformance
with other requirements stated or reasonability implied and not covered by specific test.
6.12 Cleanliness
The inside surface of the valve shall be degreased and then flushed with clean filtered
deminerilised water. The surface shall be visibly clean. The degreasing agent / detergent used for
cleaning shall be less than 25 PPm. of halogen.
7.0 DOCUMENTATION
The contractor shall submit following documentation to the purchaser.
a) Instruction & service manuals covering installation, operation and maintenance of valves &
operation and maintenance of valves & operators.
b) Assembly & component drawing.
c) Inspection history docket
d) One set of micro film for all approved drawings along with one set of reproducible.
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8.0 PREPARTION FOR SHIPMENT
All valve shall be prepared for shipment in accordance with the instruction stated below.
The interior of the valve shall be clean and dry.
All exterior finished or machined carbon steel surfaces shall be protected against corrosion with a
liberal coating of an approved easily removable compound. All machined surfaces shall be
protected against mechanical damage.
All exterior unfinished carbon steel surfaces shall be painted with one coat of a suitable paint to
be applied in accordance with the manufacturer‟s instruction, approved by purchaser. Paint shall
withstand max. service temperature as stated in respective valve specification sheet.
All openings shall be adequated sealed. Flanged opening shall be covered with a 20mm thick
plywood blank flange held in place with 4 bolts and sealed with a blank gasket of natural rubber
or equivalent.
Butt weld opening shall be closed with wooden, plastic or sheet metal covers fitted with
gaskets and sealed with an approved easily removable sealing compound. The covers
shall be securely attached by internal or external clamps or other approved means so that they will
not be dislodged by rough handling during shipping. Attachment of covers using an adhesive tape
alone is not acceptable.
Internally threaded pipe connections shall be plugged with a threaded metal plug sealed with
crane packing company thread tape 0.0125 mm thick or approved equal. No thread lubricant shall
be used. Externally threaded pipe connections shall be similarly protected with caps and thread
tape.
A perforated container of vapor phase inhibitor with maximum 25 ppm. Chloride content shall be
firmly attached to the inner surface of the cover on one end of each valve.
All components shall be tropical export packed, suitably boxed and protected from damage in
transit to the site in India. Equipment shall be prepared for a period in transit exceeding two
months.
The constructions and lining of the boxes shall provide protection for their contents. The
packaging shall also satisfy the requirements of the ocean shipping agency and shall include
adequate cushioning, blocking, bracing, shedding hoisting and the tie-down provisions. The
packaging shall be subject to the approval of the purchaser.
9.0 SPECIFIC REQUIREMENTS
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9.1 Gate valve
To facilitate application of constant load on the gland packing, a line loading arrangement in the
form of disc springs on the gland followers shall be provided. Load vs deflection curve shall be
submitted.
The gate valves are required to operate under critical emergency condition and hence the design
shall be chosen for highest reliability for performance, under isolated conditions the valve shall be
capable of providing highest seat leak tightness. Accordingly, the bidders may quote for wedge
type (Flexible / split ) or parallel slide type design. All valve shall be provided with back seats.
Hold up volume inside the valve and pressure drop across fully open valve shall be as minimum
as practicable. For ejection of stem packing material by application of hydraulic / pneumatic
pressure a connection to the base of stuffing box shall be provided.
9.1.1 Actuator for gate valve
Closing / opening time for power operated valves shall not be greater than the values indicated in
the respective valve specification sheets. The contractor shall choose the type of actuator to meet
the specified stroking speeds, operational reliability and specified service conditions.
9.2 Check valves
All check valves shall be swing check type. If specified in the respective valve specification
sheets, provision shall be made for manual operation for operability check.
The design shall ensure the perfect seating of disc with seat for zero differential pressure
condition across the valve.
9.3 Butterfly Valves
The design of the valves shall be compact. Wafer type of valve body is preferred. Valves shall be
designed as per NC-3512.2 and for installation between R.F flanges of corresponding pressure
temperature rating meeting the requirements of ANSI B16.5 No part of the internals shall extend
beyond the body ends when the disc is in closed position. Resilient seating shall be provided on
the periphery of the valve body with proper clamping arrangement. The seating material shall be
compatible with service condition indicated on the individual valve spec. sheets and other
requirements of the specification & the same shall be subjected to purchaser‟s approval. The
contractor shall also provide a procedure for removal and replacement of seat.
9.3.1 Actuators for butterfly valves.
The contractor shall choose the type of actuator to meet the requirements of this specification and
having compatibility with service conditions stated in valve spec sheets. Piston with spring type of
actuator is also acceptable.
9.4 Plug / Ball Valves
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Plug/Ball valve shall be non lubricated type and design shall be such that as minimum torque as
practicable shall be needed for opening & closing of the valve. The valves design shall be chosen
for highest reliability for performance.
9.4.1 Actuator for Plug/Ball valves
The contractor shall choose the type of actuator to met the requirements of this specification.
Piston with spring type qualified actuator is also acceptable.
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ANNEXURE-I
Requirement of Extension fitted to the valve
1.0 General
Extensions to valve bodies or other items of equipment are required when indicated on individual
specification sheets. Attachment of extensions will generally be by means of full penetration butt
welds. Seal-welded threading and socket (i.e fillet ) welding is permitted only when specified on
individual specification sheets.
The types of extensions required, whether pipe nipple and / or other pipe fittings are indicated on
specification sheets.
2.0 Dimensions
The schedule number, or rating for each extension is indicated opposite the heading “END
CONNECTIONS” on the specification sheets.
The lengths of extensions are given on the specification sheets in one of the two following
methods.
The lengths of extensions are given on the specification sheets in one of the two following
methods.
a. Each extensions sized individually
b. An overall length given which includes the end-to-end dimension of the valve or other
item of equipments, and which implies equal extension lengths in cases where two extensions are
specified.
3.0 Material
The material specification for extensions are shown on individual specification sheets. The ASME
specification required are
a. Carbon steel SA 333 Grade 6
b. Stainless Steel ASTM A 376 TP 304L
On All carbon steel extension, the material specification shall be marked legibly, using low stress
stamps, on the external surface. On all stainless steel extensions the material specification shall be
etched legibly into the external surface.
All extensions shall be inspected as required by Table-1 in Section 5.6 herein.
4.0 Welding
All welds shall be performed by a welder who is qualified under the ASME code. The weld
procedure shall also be qualified under the code. All welds shall meet the requirements of Section
5.2.2 herein.
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Inspection and acceptance of full penetration welds shall be in accordance with the requirements
shown in table 1 of section 5-6 herein.
Fillet and seal welds “ When completed, the weld shall have a smooth and uniform appearance
with no undercutting, over lap or cracks, and shall be completely fused. Seal welds shall cover all
external threads entirely.
All fillet and seal weld shall be inspected by the liquid penetrant method or by the magnetic
particle method and shall show no signs of defects.
In the event of any weld failing to pass inspection, repair and subsequent re-inspection shall be
carried out with permission from purchaser.
In order to obtain butt welds of the quality specified above, the use of GTAW using consumable
insert welding procedure is recommended.
5.0 END CONNECTION
The outer ends of all extensions shall be prepared as detailed on purchaser‟s drawing EDG-B1
sheet No-38 to the size and schedule specified under the heading “END CONNECTIONS “ on
individual valves specification sheets.
Ref.:- Indent CC no. 72889
Compliance Sheet for Stop Check Valve (To be filled & endorsed by bidder)
Authorized Signature with seal For & on behalf of bidding firm
Sl. No.
Para meter Specification Compliance by Bidder
1. Make & Model To be specified by bidder (Catalog / pamphlet / drawing attached)
Yes / No
2. Design Type T- Pattern, piston type, Bellow sealed, Stop check valve i.e. non return valve with hand wheel facility to stop flow.
Yes / No
3.
Design & Test Code ASME Section-III NB & ANSI B16.34 Yes / No
4.
Design suitable for specified operating/ extreme condition in Valve specification sheet
Supplier commits to submit design conformity certificate while delivery of item.
Yes / No
5 Product drawings Primary drawing with MOC enclosed with bid and final drawing to be submitted immediately after receipt of PO.
Yes / No
6. Inspection & Testing QAP Party shall provide tentative QA plan for approval.
Yes / No
7.
Delivery of items along with history docket , drawing, installation & maintenance manual
All In agreement with tender doc / condition as mentioned in VSS and shall be the part of item.
Yes / No