sp-2154 - valves technical specification

Petroleum Development Oman L.L.C.

Document title:

Document ID SP-2154

Document Type Valves Technical Specification

Security Unrestricted

Discipline Mechanical Static/Piping

Owner Abdulnabi Al-Balushi, UEP/1S

Issue Date 15-July 2013

Version 0

Keywords: This document is the property of Petroleum Development Oman, LLC. Neither the whole nor any part of this document may be disclosed to others or reproduced, stored in a retrieval system, or transmitted in any form by any means (electronic, mechanical, reprographic recording or otherwise) without prior written consent of the owner.

Petroleum Development Oman LLC

Revision: 0 Effective: July-13

Page 2 Valves Technical Specification 15/07/13

The controlled version of this CMF Document resides online in Livelink. Printed copies are UNCONTROLLED.

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ii Revision History

The following is a brief summary of the 4 most recent revisions to this document. Details of all revisions prior to these are held on file by the issuing department.

Version No. Date Author Scope / Remarks

0 15 July 2013 Mahesh Manjakuppam Srinivasan First Issue

iii Related Business Processes

Code Business Process (EPBM 4.0)

EP 64 Design, Construct, Modify or Abandon Facilities

iv Related Corporate Management Frame Work (CMF)

Documents

The related CMF Documents can be retrieved from the Corporate Business Control Documentation Register CMF.





TABLE OF CONTENTS

i Document Authorisation ......................................................................................................... 3

ii Revision History ..................................................................................................................... 4

iii Related Business Processes ................................................................................................. 4

iv Related Corporate Management Frame Work (CMF) Documents ........................................ 4

1 Introduction ............................................................................................................................ 6

1.1 Purpose ............................................................................................................................ 6

1.2 Changes to the Specification ............................................................................................ 6

1.3 Exceptions ........................................................................................................................ 6

1.4 Reference Documents ..................................................................................................... 6

2 General requirements: ........................................................................................................... 7

2.1 Design and Construction .................................................................................................. 7

2.2 Seat and Sealing .............................................................................................................. 7

2.3 Valve Operator ................................................................................................................. 8

2.4 Valve lifting and supporting provision ............................................................................... 9

2.5 Weld overlay ..................................................................................................................... 9

2.6 Vent / Drain Connection ................................................................................................... 9

2.7 Painting and Coating ........................................................................................................ 9

2.8 Sub Contracting ................................................................................................................ 9

3 Special Services ................................................................................................................... 10

3.1 ESD/IPF/HIPPS Ball Valves ........................................................................................... 10

4 Inspection and Testing ......................................................................................................... 11

4.1 Additional Inspection / Testing Requirements: ............................................................... 11

4.2 TAT requirements: ......................................................................................................... 11

5 Appendix A - Glossary of Definitions, Terms and Abbreviations ......................................... 12

6 Appendix B Typical Lip seal Arrangements ...................................................................... 13

7 Appendix C Typical Arrangements of CRA sleeve weld detail in drain / vent port of Weld overlay valves: ............................................................................................................................. 15

8 Appendix D Typical arrangements of Vent and Drain with threaded plug: ........................ 16

9 Appendix E User Feedback Page ........................................................................................ 17





1 Introduction

1.1 Purpose This specification shall apply to on plot valves (MESC and Non-MESC categories) in addition to the applicable International codes, MESC specification, SHELL SPE and technical requisition. The purpose of this specification is to upgrade the valve integrity in terms of reliability and safety.

1.2 Changes to the Specification This specification shall not be changed without approval from the Custodian, CFDH Mechanical (Static), who owns this specification. If you think any part of this specification is not correct, write your comments on a copy of the User Comments Form. The form is included as the last page of this specification. Send the copy with your comments and personal details to DCS after discussion with (CFDH Static).

1.3 Exceptions Any proposed exceptions or variations to this specification shall be submitted to the Company or its representative for approval prior to manufacture. In case of any conflict between the requisition/datasheet and this specification, vendor shall seek approval from the Company. Any work completed with unauthorised modifications may be rejected by the Company. Any subsequent re-work shall be in accordance with this specification and shall be to the Manufacturers/Suppliers account.

1.4 Reference Documents

API 6D Specification for pipeline valve

ISO 14313 Petroleum and Natural Gas industries - Pipeline transportation system Petroleum and Natural Gas industries-Pipeline valves

API 6A Specification for Wellhead Equipment

ASME B16.34 Valves Flanged, Threaded and welding end

ASME B16.10 Face to Face and End to End Dimensions of valves

DEP 30.00.60.13-Gen Human Factors Engineering-Valves.

SPE77/313 Valves with CRA Cladding

SPE77/312 Fugitive Emission Production Testing

SPE77/302 Valves-General requirements

SP1246 Specification for Painting and Coating of Oil and Gas Production Facilities

SP1173 Welding of Metals





2 General requirements:

2.1 Design and Construction Vendor shall have performed required design calculations for all the valves for which they are approved in the PDO PGSC list. The detailed calculation report should be made available if required by company or buyer at any time of execution of job. FEM analysis shall be performed for all the valve categorised to API 6A rating and materials not listed in the ASME B 16.34.

For carbon steel valve, minimum 3 mm corrosion allowance shall be considered in the design unless other wise specified in the requisition. The cast body of valve shall not have any sharp contour which may see crack, shrinkage and blow hole as the molten materials may not flow smoothly to the sharp corner of the valve during casting.

As an alternative to top entry flanged end ball valve vendor can opt for the two (2) piece valve design if vendor has got good past record for such design.

2.2 Seat and Sealing

If the seal material specified in the requisition as thermoplastic, it shall be of Lip seal type with Eligiloy 718 spring material. Chevron pack may be acceptable for stem sealing. If the seal material is specified as elstomeric materials it shall be AED (Anti Explosive decompression) type. Vendor shall have the material specification and EN10204 2.1 certificates for the type seal proposed in the valve and if Company / buyer requests at any time during execution of job shall provide the same for information/reference.

Refer Annexure-B for the typical arrangement of lip seal arrangement in the ball valve. Ball valve Seat ring shall have primary lip seal with a fire safe graphite ring. The Valve rated API 10000# and above shall be metal seated and zero seat leakage across the valve as per API 6A. The hard facing of metal seated high pressure ball valves (ASME 1500 # and higher) shall be with Tungsten carbide or Chromium carbide. The temperature limit for the tungsten carbide is max. 200 DegC, for higher temperature Chromium carbide shall be used. The requirements of hard face coating of tungsten carbide (TC) or chromium carbide shall be: - Thickness of minimum 400 microns after grinding and polishing. - Tensile bond strength > 10,000 psi - Min. Hardness 1050HV.

For CS ball valve with trim material of DSS or SDSS or Alloy 825 construction, the seal pocket of static/dynamic lip seal or chevron seal shall be with Alloy 625 weld overlay. If vendor is unable to carry out weld overlay on the seal pocket areas in the smaller size of valve, the valve body/bonnet shall be supplied with the same material of trim. The body/bonnet joint shall have primary static seal or gasket suitable for the designated pressure class and secondary static seal which is of fire safe gasket/seal. No O ring is allowed in the Body /bonnet joint





2.3 Valve Operator

Manually operated valves shall be operated by a lever, wrench or hand wheel. The direction of operation shall be clockwise for closing the valves. The maximum force required to initially crack open a valve at maximum differential pressure with a hand wheel or lever of more than 125 mm (5 in) in diameter or length shall not exceed 445 N (100 lbf), as measured on the rim of the hand wheel or the end of the lever or wrench. For hand wheels or levers between 50 mm (2 in) and 125 mm (5 in) in diameter or length(i.e. intended for one-handed operation) the maximum force shall not exceed 66 N (15 lbf),as measured on the rim of the hand wheel or end of lever or wrench. The maximum dimension of hand wheel and lever shall be according to requirements of ISO 14313 except the maximum hand wheel diameter is limited to 800mm and the maximum lever length is limited to 450mm. Gear Operator shall be provided for manual valves in accordance with the following table:

ASME

Class

Valve Type

Gate Globe / Plug Ball Butterfly

150 DN 350

(NPS 14) and larger

DN 250 (NPS 10) and larger



300 DN 300 (NPS

12) and larger




600 DN 150 (NPS 6)

and larger DN 200 (NPS 8)


and larger

900 DN 100 (NPS 4)



and larger

1500 DN 100 (NPS 4)



and larger

=>2500 DN 80 (NPS 3)



and larger

NOTES: 1. Valve torques can vary for different manufacturers and shall be checked to ensure appropriate selection of gear operators based on the maximum and sustained force requirements provided in this specification...

2. Manufacturers can provide gear operators for lesser size also as per their standards...

Table 1.0

Valve that requires more than 100 turns to go from fully open to fully closed should be equipped with actuators (hydraulic, electric or pneumatic) or mobile operators upon approved by company. The gear box output torque rating shall be at least 1.5 times the maximum required operations torque of the valve. Gear operator shall be heavy duty, totally enclosed, grease-filled, self-locking type, and dust and weather proof to IP 55, suitable for outdoor installation. [Where specified, the gear enclosure shall be water proof/splash proof to IP 65.] The gear operator shall be adjustable at 45 degree increments in the field





2.4 Valve lifting and supporting provision

Valves of sizes 8NPS (200NB) and above or 250Kg and heavier shall be equipped with lifting lugs. Tapped holes and eye bolts shall not be used for lifting. Lifting lugs position shall allow for safe handling of valve with Gear box or actuator. Valve shall have saddle or leg bottom support for the valve weighing more than 750kg with gear box/actuator and the supports should be designed to take care of the vertical and lateral loads of valves with operators. The support height shall be as minimum as possible.

2.5 Weld overlay

For top entry ball valves, the internal CRA weld overlay in the body /bonnet is applicable only for size 8 inch and above. The 6 inch and smaller valve size shall be of solid CRA material.

If stellite is specified as hard facing, it shall be weld overlay and minimum finished thickness of welded-on hard facing material shall be 3.0 mm, unless otherwise specified...

The weld overlay of valve body vent /drain port shall be similar to the arrangement shown

in the Annexure-C.

2.6 Vent / Drain Connection

The plug material shall be same as the trim material. If the drain port is at the bottom most portion of the body, the plug shall be extended to full length of port so that no

accumulation of solid particles / debris is entrapped in the drain port. Refer Annexure-D

No seal welding should be performed on the plug after shop or field Hydro testing. The vent /drain plug shall have threaded cover cap as shown in the sketch.

The minimum size of flanged vent and drain port shall be one (1) inch. The flanged connections shall be butt welded to the body or pad type flanged. No socket welded pipe with flange connection is permitted.

2.7 Painting and Coating

The painting and coating of valve body shall be as per SP-1246. The Alloy 625 /825 / Alloy28 body does not require any coating / painting.

The valve bolting (B7 / B7M) shall be with ENP + PTFE top coated for the design temperature less than 200 Deg C.

Valve ends shall be covered with close fitting protectors made of plastic caps to protect the machined parts and prevent ingress of dirt and moisture.

2.8 Sub Contracting

All valves are deemed to be machined, assembled and tested at the company approved premises. Any deviation to this, requires a prior approval from the company, which must be obtained at the time of bidding stage.

If any works are outsourced after company approval, the manufacturer shall maintain full QA/QC control over sub contracting activities.

The sub contractor of Weld overlay works shall be approved by company prior to commence any weld over lay works.





3 Special Services

3.1 ESD/IPF/HIPPS Ball Valves

The valve shall be of trunnion type with metal seat arrangement and minimum size of 2 inch. The upstream seat shall be with single piston effect and down stream seat with double piston effect. The SP (single Piston) and DP (Double Piston) shall marked permanently on the respective seat side and flow arrow shall be embedded on the body. However, the valve shall be suitable for bi-directional isolation..

The Seat ring shall have primary lip seals (2 nos.) with a fire safe graphite ring. The stem side shall have minimum two (2) primary lip seals or U or V shaped packing with fire safe secondary seals. The grease fitting shall be provided between primary and secondary seal on the stem side with two in- built check valves. The Grease thread fitting shall be anti blow out plug type and with two (seals). The material of grease fitting shall be same of valve trim material.

No seat sealant injection shall be provided for these valves.





4 Inspection and Testing

4.1 Additional Inspection / Testing Requirements:

Vendor shall not commence the manufacturing of valves unless the ITP is approved by company or buyer.

The duration of shell test shall be as per ISO 14313. However, 2% of valve from each category of ordered lot shall be tested with minimum test duration of 1 hour for high pressure shell test:

The minimum duration of high pressure seat leak test shall be 5 minutes for all size of valves and one (1) valve from each category shall undergo 30 minutes seat test. In the event of failure, the valve shall be repaired and retested and another two (2) valves from same category to be selected in random for 30 minutes seat test.

2% of valve from each category shall be tested as per B11/B12 of ISO 14313 in case the valves are identified with single and double piston effect combination or both seats are with double piston effect.

All but end valves shall be considered as IC-IV of SPE 77/302.

The API 6A rated valves used for gas service shall be minimum comply with PSL3G and PR2 requirements.

The ITP shall include minimum the following activities:

- Materials inspections/ testing( body/bonnets/closure members/stem/bolts/nuts/seals) - Soft seat material certificates. - Visual inspections(rough / machined ) - WPS /PQR for the weld overlay - Required NDEs for the valve and weld overlay. - Test and inspection of hard facing including sample bond /hardness test. - All required testing on assembled valves including valve stem torque tests, cavity relief

tests,, - Inspection /testing of Painting (Visual/thickness/ adhesive). - Tagging and marking - Visual inspection prior to packing(internal/external/ fittings on the valve body) - Preservation and Packing.

4.2 TAT requirements:

The TAT as per SPE 77/300A is mandatory which shall be witnessed by PDO or PDO approved TPI in case the valves were not already qualified by SHELL with TAT. If the waiver to TAT is required, vendor shall fully comply with the following requirements in addition to MESC, SPE 77/302 and section 4.1 of this specification.

- All the valves irrespective of materials and service shall be assigned IC-IV for the class above 600# and IC-III for the class 600# and below or as per inspection criteria of SPE 77/302, whichever is stringent.

- The soft seal material (Lip seals) material shall be from Saint-Gobain and provide 2.2 material certificates for TPI witness prior to assemble the valves.

- All valves shall undergo production FE (Fugitive Emission) testing. - The final inspection and testing including visual inspections prior to packing shall be in

accordance with ISO 10474 3.1C certificate or EN10204 3.2.

TPI shall be involved in all inspection / testing which shall be at vendor cost and vendor shall get company approved on TPI.





5 Appendix A - Glossary of Definitions, Terms and

Abbreviations

A.1 Terms and Definitions

Companyr

Buyer

Petroleum Development Oman LLC. The Company may also include an agent or consultant authorised to act for and on behalf of the Company. EPC/EMC/ODC contractors.

Corporate Functional

Discipline Head

The person within the Company responsible for the discipline to which the standard belongs

Manufacturer/Supplier

The party which manufactures or supplies equipment and services to perform the duties specified by the Company.

User

The Company Manufacturer/Supplier or Consultant that uses this document.

shall Indicates a requirement.

should Indicates a recommendation.

may Indicates a possible course of action.

Fire tested design A design subjected successfully to fire testing

Fire safe design A design that by the nature of its features and materials is capable of passing a fire test

A.2 Abbreviations

ASME American Society of Mechanical Engineers

BCD Business Control Document

CFDH Corporate Functional Discipline Head

DCS Document Control Section

NDE Non Destructive Examinations

IPF Instrument Protective function

HIPPS High Integrity Pressure protective system

ENP Electroless Nickel Plating

ESD Emergency Shut Down

MPI Magnetic Particle Inspection

RED Requisition for Engineering Documents





6 Appendix B Typical Lip seal Arrangements

Typical Ball Valve Body/Bonnet arrangement with Lip seal

Typical Stem side seal Arrangement with Lip seals





Typical Arrangement of Lip seal on the ball valve seat ring

Note : 1.The arrangement shown in the above sketch is just representative only. Vendor should provide

as per their approved standards meeting all the required specifications.

2. The Lip seals provided on the CS body / bonnet, the seal pocket shall be weld overlay as per

section 2.2





7 Appendix C Typical Arrangements of CRA sleeve weld detail in drain / vent port of Weld overlay valves:

Note

1: The arrangement shown in the above sketch is just representative only.

2: The sleeve shall be with Anti blow out arrangement.

3:.Drilling of port shall be done after completion of internal body weld overlay.

4: The sleeve should be cold fitted.





8 Appendix D Typical arrangements of Vent and Drain with threaded plug:





9 Appendix E User Feedback Page

SP-2154 VALVES TECHNICAL SPECIFICATION USER FEEDBACK FORM

Any user who identifies an inaccuracy, error or ambiguity is requested to notify the custodian so that appropriate action can be taken. The user is requested to return this page fully completed, indicating precisely the amendment(s) recommended.

Name:

Ref ID Date:

Page Ref: Brief Description of Change Required and Reasons

To: UEP/10S - Mahesh Manjakuppam Srinivasan

Custodian of Document Date:

sp-2154 - valves technical specification

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