sp-2154 - ver 1

PetroleumDevelopmentOmanL.L.C.

Documenttitle:

DocumentID SP2154

DocumentType ValvesTechnicalSpecification

Security Unrestricted

Discipline MechanicalStatic/Piping

Owner AbdulnabiAlBalushi,UEP/1S

IssueDate 15July2014

Version 1

Keywords:ThisdocumentisthepropertyofPetroleumDevelopmentOman,LLC.Neitherthewholenoranypartofthisdocumentmaybedisclosedtoothersorreproduced,storedinaretrievalsystem,ortransmittedinany formbyanymeans (electronic,mechanical, reprographic recordingorotherwise)withoutpriorwrittenconsentoftheowner.

Petroleum Development Oman LLC Revision: 1

Effective: July-14

Page 2 Valves Technical Specification 15/07/2014

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

This page was intentionally left blank


Effective: July-14



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

1 15 July 2014

Mahesh Manjakuppam Srinivasan Second 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.


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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 Priority documents ..................................................................................................................... 6

1.4 Exceptions .................................................................................................................................. 6

1.5 Reference Documents ............................................................................................................... 6

2 General requirements: ..................................................................................................................... 8

2.1 Design and Construction ............................................................................................................ 8

2.2 Seat rings, Stem and Sealing (For ball valves) .......................................................................... 8

2.3 Seal Materials ............................................................................................................................ 9

2.4 Valve Operator ........................................................................................................................... 9

2.5 Valve lifting and supporting provision ...................................................................................... 10

2.6 Weld overlay ............................................................................................................................ 10

2.7 Vent / Drain Connection (For ball valves) ................................................................................ 10

2.8 Painting and Coating ................................................................................................................ 11

2.9 Sub Contracting ....................................................................................................................... 11

3 Special Valves ............................................................................................................................... 12

3.1 ESD/ HIPPS Ball Valves (Additional requirements) ................................................................. 12

3.2 Choke Valves (Additional requirements) ................................................................................. 12

4 Inspection and Testing ................................................................................................................... 13

4.1 Inspection / Testing Requirements: ......................................................................................... 13

4.2 TAT (Type Acceptance Testing) requirements: ....................................................................... 14

5 Appendix A - Glossary of Definitions, Terms and Abbreviations ................................................... 15

6 Appendix B Typical Lip seal Arrangements ................................................................................ 17

7 Appendix CTyp. Arrang. of CRA sleeve weld detail in drain/vent port of Weld overlay valves: .. 19

8 Appendix DTypical arrangements of Vent and Drain with threaded plug or flanged connection: 20

9 Appendix E- Points to be clarified in TBE ...................................................................................... 21

10 Appendix F- User Feedback Page ................................................................................................. 22


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1 Introduction

1.1 Purpose This specification shall apply to on plot valves (MESC and Non-MESC categories) under Hydrocarbon / sour / toxic / steam service. This is 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. In general the specification is applicable for Ball, Gate, Globe, DBB valve and Triple Eccentric Butterfly valve.

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 Priority documents In case of conflict between documents relating to an enquiry or order the following priority of documents shall apply:

This document PO / Requisition Sheet and Project Specification. Standards, Specifications and Codes referred to in this document.

1.4 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.

1.5 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

ISO 17292 Metal ball valves for petroleum, petrochemical and allied industries

ISO 10434 Bolted bonnet steel gate valves for the petroleum, petrochemical and allied industries

ISO 15761 Steel gate, globe and check valves for sizes DN 100 and smaller, for the petroleum and natural gas industries

BS 1868 Specification for Steel check valves (flanged and butt-welding ends) for the petroleum, petrochemical and allied industries


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BS 1873 Specification for Steel Globe and Globe Stop and Check Valves (Flanged and Butt-Welding Ends) for the Petroleum, Petrochemical and Allied Industries

API 609 Butterfly Valves: Double-flanged, Lug- and Wafer-type

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

ASME B31.3 Process Piping

BS EN 10204 Metallic products Types of inspection documents

ISO 10474 Steel and Steel Products- Inspection documents

DEP 30.00.60.13-Gen Human Factors Engineering-Valves.

SPE77/130 Ball valves (Amendments/Supplements to ISO 14313)

SPE77/300A Synopsis of Procedure and Technical specification for Type Acceptance Testing (TAT) of Industrial valves

SPE77/313 Valves with CRA Cladding

SPE77/312 Fugitive Emission Production Testing

SPE77/302 Valves-General requirements

SP-2041 Selection of cracking resistant material for H2S containing Environments

SP-1246 Specification for Painting and Coating of Oil and Gas Production Facilities


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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 otherwise 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. For the valves of multi-piece construction e.g. a three-piece ball valve, wall thickness shall be based on Paragraph 6.1.2 (c) of ASME B16.34 Latest version. The API 6A rated valves used for gas service shall be minimum comply with PSL3G and PR2 requirements.

2.2 Seat rings, Stem and Sealing (For ball valves) The stem or shaft retainer ring or collar shall be integral with the stem. Stem or shaft retention by means of body/stem threads are not allowed. If the seal material specified in the requisition as thermoplastic, it should be of Lip seal type for ball valves. PTFE flat ring, instead of Lip seal on stem side is acceptable for the floating Ball valves, if vendor qualifies his design with TAT. Chevron or V pack may be acceptable for stem sealing in lieu of Lip seals, If the seal material is specified as elastomeric materials it shall be AED (Anti Explosive decompression) type. Refer Appendix-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 without secondary graphite seal on the seat side may be acceptable. If vendor qualifies such design with fire safe design test. The metal seated ball valve shall have hard facing with satellite-6 or Tungsten carbide or chromium carbide. 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 C, 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 250 microns after grinding and polishing. Tensile bond strength > 10,000 psi Min. Hardness 1050HV.

The ball Valve rated API 10000# and above shall be metal seated.

For CS ball valve with trim material of DSS or SDSS or Alloy 825 / 625 construction, the seal pocket of static/dynamic lip seal or chevron seal shall be with Alloy 625 weld overlay in accordance with MESC SPE 77/313. If vendor is unable to carry out weld overlay on the seal pocket areas in the smaller size of valve (like 2 inch and below), the valve body/bonnet shall be supplied with the same material of trim.


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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 (elastomeric) is allowed in the Body /bonnet joint as pressure containing seal.

2.3 Seal Materials Spring for the Lip seal shall be of Eligiloy (UNS R30003) material. The make of the lip seal may be Saint Gobain / GFD / ESA srl. The recommended elastomeric O-ring material is Viton-AED type (James Walker Type 58/90, James Walker Type 58/98). Vendor shall have the material specification and EN10204 2.1 certificates for the type of seal proposed in the valve and if Company / buyer requests at any time during execution of job shall provide the same for information/reference.

2.4 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 500 mm. 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 DN 100 (NPS 4)

and larger



and larger



and larger

=>2500 DN 50 (NPS 2) and larger DN 50 (NPS 2)


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.

3. The size indicated in the table represents flange size.


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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 180 degree increments in the field.

2.5 Valve lifting and supporting provision Valves of sizes 8NPS (200DN) and above or 250Kg and heavier shall be equipped with lifting lugs. Lifting provision shall be designed with supporting calculations and weight bearing data. Lifting provision 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.

2.6 Weld overlay For top entry ball valve with requirements of CRA body & bonnet, the CRA internal weld overlay shall be done, only for size 8NPS (200DN) and above.

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. However for small bore valves (2 NPS and below), 1mm thickness is acceptable. The hard facing shall be as per SPE 77/302(latest).

The weld overlay of valve body vent /drain port shall be similar to the arrangement shown in the Appendix-C.

2.7 Vent / Drain Connection (For ball valves) Flanged or threaded vent and drain connection shall be selected based on the requirement specified in the MESC SPE 77/130.

The minimum size of threaded vent and drain connection shall be as per Table 7 of API 6D/ISO 14313.

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 Appendix-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. If a pad type flanged connection is applied, it may be integrally machined with the valve body. The bolting, gasket and flange rating shall be same as for the valve.

Vendor shall show the details of vent / drain arrangement in the valve general arrangement drawings for company approval.


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For smaller size of valves (4 NPS, 300# and below) the drain can be utilised as vent and can avoid separate provision of vent.

2.8 Painting and Coating The painting and coating of valve body shall be as per SP-1246. Type of coating system shall be selected based on the design temperature of the valve. The Alloy 625 /825 / Alloy28 body does not require any coating / painting. Coating requirement of SS/DSS material shall be based on project specific material selection report.

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.

2.9 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 of any weld over lay works.


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3 Special Valves

3.1 ESD/ HIPPS Ball Valves (Additional requirements)

These additional requirements are applicable only for the HIPPS & plant boundary ESD valves. These valves shall be of trunnion type with metal seat arrangement and minimum size of 2 NPS. The upstream of the valve seat shall be with single piston effect and the downstream seat with double piston effect. The SP (single Piston) and DP (Double Piston) shall be 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 on the DPE side. Single Lip seal is acceptable on the SPE side. 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.

3.2 Choke Valves (Additional requirements) Choke valves shall comply with PSL/PR requirements as follows

Valves used for sweet gas service or with ASME class 1500# shall be minimum comply with API 6A PSL2 and PR1 requirements.

Valves used for sour gas service or ASME class >1500# & 2500# shall be minimum

comply with API 6A PSL2 and PR2 requirements.

Valves used for ASME class >2500# shall be minimum comply with API 6A PSL3G and PR2 requirements.

Flow characteristic shall be of equal percentage characteristic.

Choke valve shall comply with fugitive emission Class B as per SPE 77/312.

The valve material requirements for choke valves shall fully comply with SPE 77/302

(Valve General Requirements).


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4 Inspection and Testing (Applicable for Ball, Gate, Globe, DBB valve and Triple Eccentric Butterfly valve)

4.1 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 (at 1.5 times of rated pressure) shall be as per ISO 14313. However, valve samples from each category (Based on PO, Type, Material, size, rating) of ordered lot shall be tested with minimum test duration of 1 hour for high pressure shell test. High pressure shell test for 1 hour duration shall be at rated pressure instead of 1.5 times of rated pressure and this requirement is applicable only for all casting valves. Criteria for selecting the number of samples for each category shall be as per the below requirement.

If valve quantity in each category is:

(a) >10 & 500 & 1000, then 10 nos. of valves shall be selected for testing.

The minimum duration of high pressure seat leak test (at 1.1 times of rated pressure) shall be 5 minutes for all size of valves and one (1) valve from each category shall undergo 15 minutes seat test at rated pressure. 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 15 minutes seat test.

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

All butt end valves (Both forging and casting) shall be considered as IC-IV of SPE 77/302.

For metal-seated ball valves, a low-pressure gas seat test shall be executed in accordance with Annex B.3.3 of API 6D/ISO 14313 specification. However the acceptance leakage rate shall be in accordance with ISO 5208 Rate B.

For all the ball Valves rated API 10000# and above, seat leakage criteria shall be PSL 3G as per API 6A. For steam service valves, the TAT as per SPE 77/300A is mandatory and no waiver is applicable. In addition 2% or 5 nos of valve whichever is lesser shall undergo elevated temperature seat test at rated pressure.

The ITP shall include minimum the following activities:

Materials inspections/ testing( body/bonnets/closure members/stem/bolts/nuts/seals) Soft seat material certificates (EN10204 2.1). 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/ adhesion). Tagging and marking Visual inspection prior to packing(internal/external/ fittings on the valve body) Preservation and Packing.


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4.2 TAT (Type Acceptance Testing) 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 applicable to each of the specific Purchase Order.

All the cast & forged valves irrespective of materials shall be assigned IC-IV for the class above 900# and IC-III for the casting valves class 900# and below or as per inspection criteria of SPE 77/302, whichever is stringent.

For ball valves the soft seal material (Lip seals) material shall be from Saint-Gobain or GFD and provide 2.1 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 3.2 certificate or EN10204 3.2. TPI shall be involved in all inspection / testing which shall be at vendor cost and the TPI agency shall be PDO approved one


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5 Appendix A - Glossary of Definitions, Terms and Abbreviations

A.1 Terms and Definitions Company 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

HIPPS High Integrity Pressure protective system

ESD Emergency Shut Down

MPI Magnetic Particle Inspection

RED Requisition for Engineering Documents

TBE Technical Bid Evaluation

CRA Corrosion Resistant Alloy

EPC Engineering, Procurement and Construction

EMC Engineering and Maintenance services Contract

ODC Off-plot Delivery Contract

MESC Material and Equipment Standards and Code

PGSC Product Group Service Code


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DSS Duplex Stainless Steel

SDSS Super Duplex Stainless Steel

NPS Nominal Pipe Size

DN Diameter Nominal

PTFE Polytetraflouroethylene

ISO International Standards Organization

ITP Inspection & Test Plan

WPS Welding Procedure Specification

PQR Procedure Qualification Record

TAT Type Acceptance Testing

TPI Third Party Inspection


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6 Appendix B Typical Lip seal Arrangements

Typical Ball Valve Body/Bonnet arrangement with Lip seal

Typical Stem side seal Arrangement with Lip seals


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Typical Arrangement of Lip seal on the ball valve seat ring

Notes: 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. 3. The requirement of 2 nos. of primary lip seals for seat ring is applicable for DPE seat. Single

lip seal is acceptable for SPE seat. 4. Secondary fire safe Graphite seal on seat side may not be required, if vendor qualifies his

design with the fire safe certificate.


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7 Appendix CTyp. Arrang. of CRA sleeve weld detail in drain/vent port of Weld overlay valves:

Notes:

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. Vendor to

ensure concentricity of drill. 4. The sleeve should be cold fitted.


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8 Appendix DTypical arrangements of Vent and Drain with threaded plug or flanged connection:

THREADED VENT AND DRAIN DETAIL


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9 Appendix E- Points to be clarified in TBE

SP-2154 VALVES TECHNICAL SPECIFICATION Points to be clarified in TBE for Critical / Bulk orders.

GENERAL

1. Capacity of the factory along with the current work load for the ordered period.

2. Shutdown time if any for factory / foundry.

3. Is holidays considered in the delivery schedule

4. Vendor delivery period shall mention clearly if any hold point from client side like:

i) Production will not take place unless drawing approved.

ii) Production will not take place unless ITP approved.

5. Location where the machining, testing (In house or outsourced) will be done shall be clearly mentioned.

6. Sub vendors name and location for Casting / forgings.

7. In the event of order, Vendors agreement for submission of the Supplier document register list on regular basis. It shall be with the revision status of the vendor documents along with the dates.

8. Agreement on vendor document turn around cycle as per the project requirement.

TECHNICAL

9. Design spec and material compliance followed for the quoted valves

10. Compliance to the Lip seal arrangement (For Stem seal, Shell seal and Seat back seal) as per the specification.

11. Minimum coating thickness (after grinding and polishing) for the metal seated valves as per the specification.

12. Compliance to valve operator requirement as per the specification.

13. Compliance to lifting and supporting provision for the valves as per the specification.

14. Compliance to Vent and Drain connection for the valves as per the specification.

15. Regarding painting and coating of valves as per the specification.

16. Compliance to additional Inspection and Testing requirements as per the specification.


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10 Appendix F- 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

UEP/10S - Mahesh Manjakuppam Srinivasan

Custodian of Document Date:

sp-2154 - ver 1

Documents

related cmf documents

controlled version

revision history

valves technical specification

priority documents

reference documents

document authorisation

printed copies