“AINICAL SPECIFICATION FOR PURCHASE REQUISITION VALVES GATE VALVES Nee Eee Deliver the Nem fo Dalvery Date wauotten eis Nosnally Latest by eaeuitog tego tetangel | MANGALORE REFINERY AND Sanuary 2013, ‘nly new eevised pageisissed. | PETROCHEMICALS LIMITED, 2. the mare of is wrety noed | MANGALORE, INDIA tie deals ese ate nap fF the roqustion The tered pages soe pt of the rial Fesivon sd shall be complied | win heavy. Rev Date By ‘Appa. Details o | omm | aL DESCRIPTION: This requisition covers the supply of complete materials, inspection, testing, packing and forwarding of valves as per the specifications, standards and applicable codes indicated / enclosed with this specification. Size | Type | Rating | Body Trim Ends Special | Quantity 20° | Gate | 150# | A105 13%Cr Flanged [No | 2 Gate 1508 PAIOS | 13%Cr Flanged | Motor 1 Hea Operated NOTES: 1. All nvateriats above to be supplied shall strictly conform to the specifications attached along- with, 2. Inspection of all materials above shall be done by Third party inspection agencies like BIL / Toyo / Lloyds Register / BV / DNV / TUV / IRS. The Thitd party inspection is in the scope of the vendor. The quote from the vendor shall be inclusive of all Third party inspection charges. 3. The material should be delivered along with the following documents. 8). Original third party inspection certificates b) Original test certificates (Mechanical property, chemical composition and heat treatment teport, supplementary tests, mandatory tests as per code, etc.). Photocopy of these certificates are acceptable, if the third party inspector has endorsed the copies. 108s sectional drawings, if applicable. °) “Rel. No, Rev. No. (09/08/2012 | VALVES FOR CRUDE SUCTION HOOK 3000002288 0 up Sheet of 2d) As per attached document submission list 4, The delivery of material will be deemed as incomplete in the absence of these certificates and may lead to rejection of material. 5. Please attach full set of specification sheets duly signed and stamped by bidder as acceptance. ‘This shall be part of the technical offer. The offer will not be accepted without the same. 6. Any deviation to MRPL terms and conditions should be specifically stated in attached deviation format, In absence of a duly filled and stamped deviation sheet it would be understood that there are no deviations and vendor has accepted all conditions in toto, 7. Torque data to be supplied by vendor after order placement. LIST OF ATTACHMEN S.No. Title 1 Mechanical DataSheet for MOV. 2. Process Datasheet 3. Actuator datasheet 4 ‘Scope of Supply and Work 5. 7 List of Documents for submission GEE ‘Standard Specification for Flanges a Specification Sheet for Gate valve 8 Standard Specification for Valves % EE Standard Specification for MOV Actuator 10. Procedure for Final Documentation U. Deviation Format Tek No. Tew, No, 1y08n0i2 | VALVES FOR CRUDE SUCTION HOOK 3000002288 6 up Shoot 2 of 2DATASHEET FOR MOV Project Number 11-0240 [Tag no wv.070102 [Quantity 4 P&ID No: MMRPLLO70-024-2252-10 Inlet fine no 20-0-70508704-R1A [Outlet line no 20-P-705087M- AYA Insulation Type Nt insulation thickness Nit Service CRUDE/LIQUIO Design pressure 35 beremzte) [Design temperature 6 lc [aP shutoff 05.23 beremate) Inlet Line NPS 20 Inlet tine Schedule 6 [Outlet line NPS 20 [Outlet fine Schedule 6 [Type of Body Gate Body Size 20 Port Size Flange NPS 20 Flange rating 150% Flange facing WARE, 125 ARH Flange MOC ASTM A105 [Body material ASTM A216 GR WED [Bonnet type EXTENOED Packing material ‘GRAPHITE [Stem materi 13 GR STEELINO CASTING) Seat trim material 13.¢R STEEL [Other wetted parts 13. cR STEEL studs: A193 GeB? Nuts (A194 Ge2tt [Gaskets SSP Wd SS316-GRAFIL Failure position FAILSAFE [Opening time/Closing time 60 SECONDSIMAN) [Gear Type Worm reduction Limit Switches required Yes-2 nos{Open/Close) Handwheel Required Fluid type Hydrocorbon Crude Fluid state Liquid Flow of liquid Minimum 400 sine Flow of liquid Normal 850 mayne Flow of liquid Maximum 2800 maine [Operating temperature 40¢ Maximum temperature esc Density in ke/m3 770320 Viscosity 2.8-30 CSt @50 degree C Prepared By CheckedDATASHEET FOR MOV Jarerata0s) lssa (Vapor pressure 7 Predicted sound level at 1m distance** Noted valve make Noted [Actuator make Note’ [Motor Make Notes Notes 1 Each MOV integral actuator shall include controls;status and necessary push ‘buttons/selector switches etc for control. 2 Minimum metric threaded cable entries shall be provided in actuator for following: i. 2nos for Open /Close Status lino for open/close command li.1 no. for field bus signal iv.1 no. for power v.A no. for spare Unused cable entries shall be plugged ” Should be less than 85 dBA 3 Vendor to fill at time of offer submission Prepared By Check[MOV for Crude Line Project MRPL-1 Project Site [Mangalore Unit/Equipment OMa&s Scheme Phi& 2 Grade Transfer Suction Hook-Up Fluid / State [Crude Liquid Location Pump House-13 Reference Number [MIRPE-1-070-02-4-9252-1-0 inlet Line Number E 20-P-705047M-ALA Tag Number Uv=0701ee Valve Duty Full Open & Full Close Control Required Local & Remote (Note-6) Local / Remote / Off Selector Switch Required intermediate Travel Limit Switch Not Required Potential Free Contacts for Indication lon remote panel (for valve open and Required r Potential Free Contacts for Indicating Required valve operation in proaress [Maximum time of Operation (Opening / 60 seconds Closing) Operating Temp °C 7) (Operating Pressure _Ksog 2 Design Temp °C 65 Design Pressure seg 35 faP Shut OFF ksog_ 35 _ 08 “RS pe Nore Noe Note-1,2,3,4 & 5 | [Note- 1. Type of MOV shall be Gate type [2. Actuator Design shall be based on AP 3. Provide Hand wheel for MOV. shut off. 4. Pressure Drop across valve shall be negligible. IS, Refer P&ID No. - MRPL-1-070-024-2252-1-0 for details. iz 6, For Remote operation only CLOSE action to be provided. ae Kodera jot Date (04/02/2012 KB/ VU AK SR Rev 0 Prepared By [Checked By Approved B MOV Data Sheet Date Sheet No.1.0 ui 12 13 14 15 16 17 2.0 2a 22 23 3.0 3 32 33 34 35 36 37 374 372 4.0 ad 42 43 44 45 iit] MOV Actuator Approved vendor List Paget /4 DATA SHEET FOR MOV ACTUATOR Part - I: PURCHASER'S DATA Site Conditions Altitude Design ambient temperature Max./Min, ambient temperature. Humidity climate Project Site MOV Tag Nos. System Conditions ‘Supply Voltage, Supply frequency System earthing Operating Environment ‘Area Classification Gas Group Temperature Class Construction Ingress Protection Painting ‘Whether 'K-Mass' type or equivalent Fireproofing required. For MOV Tag Nos. With Fireproofing rating «1000 m above MSL 40°C 37,8 °C / 16,7°C Max 91% Highly polluted ond corrosive as found in refineries, MPL Mangalore UV-070102 ABV 10%, 3ph. AC BOHz + 3% Solidity earthed Zone 2 qc 3 Flameproof Ex(d) 1P65, Epoxy base No. uv 070102 30 minutes Valve Duty, Mode of Control and Devices for Control Valve duty a. Fully open and fully closed b. Partially open and partially closed Control requirement Local / Remote / OFf selector switch ‘on MOV Actuator Compatibility for interfacing with DCS Setting of adjustable parameters of Actuotor (for 2 wire control system) Modification: Crude Suction Hook Up in OMS Hel-O240 Yes Yes Local & Remote Required Required From Field / Master station**47 48 484 482 48.3 484 485 49 4.10 4at 42 4.13 5.0 5 52 53 6.0 Modification: Crude Suction Hook Up in OMS ATO? Continuous position indication Local Remote ~ Poténtiometer / transducer for Remote continuous indication Intermediate travel limit switch Potential free contacts for indication on Remote ponel and other interlocks For Valve open position Fore Valve closed position Fore remote indication of position of Local Remote selector switch Fore availability of MOV actuator for remote Operation (contact from monitoring relay) For indicating valve operation in progress Remote emergency stop push button for Stopping actuator DCS interface for Remote control / indication: ‘Maximum time of operation Opening Closing Double compression cable glands and plugs For unused entries (To be supplied along with MOV actuator) Make of MOV actuator MOV Actuator Approved vendor List Pagei2/4 Mechanical and LCD indication required Not required Not required Required Required Required Required Required Required Required ‘As per valve data sheet As per valve data sheet Flameproof & WP type / WP type Test and Approval Certificates for Flameproof Actuators For indigenous make MOV Actuators For imported make MOV Actuators Submission of Type Test certificates along with the offer Applicable MRPL Specification CMRI test certificates, Approvals of CCE/ Other opplicable statutory Authority ond valid BIS license. icates from authorized Certification agency of country of Origin of actuators and Approvals of CCE / Other applicable statutory Authority. Yes. (Certificate Numbers. of valid dates to be indicated)70 I MOV Actuator Approved vendor List Page:3/4 Specification for electrical motor actuated Valves Special Requirements : NIL NOTES : 2. 3 NA denotes ‘Not Applicable’. ‘Area classification Zone, Gas group and temperature. class indicated at S, Nos.3.1 to 3.3 above refer to IS/IEC Standards. ‘The purchaser shall provide single point power supply to the actuator as per S, No.2.0 above, ‘Any other control supply voltage required shall be internally derived by the manufacturer within the actuator, In cose ‘Remote continuous. position indication’ is required as per S.No.4.6.2 above, the potentiometer / transducer required for position indication along with loose remote continuous position indicator shall be included in the quoted prices of respective MOV Actuator and supplied with it. Vendor shall furnish complete data for each MOV actuator along with the offer. Remote input signals for opening /closing / stopping the MOV shall be provided through the ‘momentary closing of separate potential free contacts in owner's panel, Necessary controls required for running the motor for the complete opening / closing sequence of the valve using such input signals shall be provided by manufacturer in the actuator. Vendor shall quote for Maintenance spares for two years trouble free operation & maintenance of the MOV actuators indicating recommended quantity and unit prices. Vendor shall also identify a list of such spares along with quontity required for commissioning the MOVs. Wherever it is mentioned ‘vendor’ the same shall be read as MOV Supplier’ for the activities 7. Items covered as a part of this requisition. Modification: Crude Suction Hook Up in oms — M-11-0240Uasercive iitasilal MOV Actuator Approved vendor List Page:4/4 DATA SHEET FOR MOV ACTUATOR Part - IT : DATA BY VENDOR (To be filled in separately for each actuator and furnished along with the offer) MOV Tag No. : 1.0 Actuator : 11 Make 1.2 Type & Catalogue No. 1.3 Applicable Wiring Diagram No. : 14 Valve duty : 1.5 Maximum permissible number of Open / close cycles per hour 1.6 Internal control supply used in actuator 1.7 Recommended backup HRC fuse rating 2.0 Motor 21 Make 22 a. kWrating ‘Power Consumption requirement in KVA 2.3 Rated speed in RPM 24 — Enclosure 2.5 Locked rotor (starting) current 2.6 — Rated torque (seating) current 2.7 Average load current 3.0 Basis for sizing and selection of actuator 40 Test and approved certificates 5.0 Component Makes 54 Contactors 5.2 Push buttons 53 Selector Switches 6.0 MOV Actuators suitable for 2 wire control System 6.1 Maximum No. of field units thet can be : connected to one master station 62 Maximum permissible distance from field unit = to the master station 63 Maximum number of Control inputs and Control / status outputs from each field unit ‘that can be handled through the 2-wire ‘Modification: Crude Suction Hook Up in OMSMOV Actuator Approved vendor List Control system The MOV actuator supplied shall be as per the following approved makes only, ACTUATOR |: ‘AUMA INDIA LTO. 2 UIMITORQUE INDIA LIMITED 3. ROTORK CONTROLS (INDIA) LTO Modification: Crude Suction Hook Up in OMSSCOPE OF SUPPLY AND WORK: SI | Description No Remarks/ Deviations if ony Overall Scope ‘Selection, sizing, engineering ‘Manafacturing ‘Supply of materials a spec ‘Supply of services as specified Factory Acceptance Test and Inspection of ex-foctory items ‘Supply of construction ond commissioning spares List for 2 years operational ard maintenance spares ‘Supply of consumables Pointing 1 | Pecking ond fornording TL | Specil tools nd races 12,_| Transportation 13,_| Field Service if required during start wp ond commissioning 14,_| Docunentation-(Hord copy and soft copy) 15, | Statutory Approvals os pplicable NOV Scope of Work and Supply 1] Supply of MOV along with accessories in prewired preteated condition 2, | Minimum metric threaded cable entries shall be provided in actuator for following! 2 nos for open close status no for open close command Lo. for fieldbus signal “Le for power sto spore Plag for Spare cable eniry into electric actuator Tog Nene plete( $5304) Flange goskets and stud bolts | Earthing Lug Eyebolt ‘ERP Canopy for Actuator Modification: Crude Suction Hook Up in OMS ~ M~ Vendor's Stamp and SignDOCUMENTS FOR SUBMISSION: [SINo] Description At the time of | After Order submission of quote _| placement Filed Up Dinasion Table of Naor Operated Vale t 2 [ Actuator Sizing ond selection details Z 3 | Stroke tine details v 4 [Uist of bought out tens with sub-suppliers rane ond’detola | F 3} Genero orrangement drawing ¥ portlis rome plate details “installation details “dimensional details -acight details 6 Electrical load data v 7 _____| Wiring ond termination drawings v 8 [Motor Specifications z 9 [ator datasheet Z 10 | @A/ACdocument ard QA Pen Z it | Tapection and test procedure z 12 | Trepection and test report(refer Indicative EV? of afTocked Tift Bacarenty specification for ist of tests tobe performed) 3 Procedure qualification records ~~] irl Document 14 etificate of compliance EEE ¥ (Final Document) 8 Packing and storing procedure - ‘TFinal Document) Test/Clbration/ Inspection reports ZFval Docurvent) Statutory certificates if applicable Tiral Bocier 16 ‘Material test certificates ‘¥(Final Document) 19 Certificates for enclosure protection ingress protection,EME/RFL ‘V(Final Document) protection Thatlltion ateial —Wetificaton | TOOT by | Materiel Tet material ke and correlation with | Vendor | certifiate a |e | - | moter gears. reference tes certificate indicctors int svitchesete, ruber + Operational Check Electrical Motor Operated © Visual 100% by + Vendor Valve Actuator Assembly + biesionl Vendor catalogue + Vee dimensions 08 | per jefel-| reference APr/ANst | standard + Drawings approved by ie +H = Final Inspection T. Visual 100% by ‘© Vendor test TT, Dimensional Vendor records TH, Functionl nd calration | ond + 159936 | ‘test for torque and limit | Random’ # switches by Third IV. Neload curent Pasty V.. direction of rotation | Inspection Vi. Phase reverseh cgay | VIL Responce tne test ne]. VEEL Variation of suply voltoge ond frequency DX Test on cutput shaft Xife Test XLHondhee! and outa | jee | ecuteh functioning | \ | XITRemote contact functionality test XIILHigh voltage test X1VEnsulationresistonce testSTANDARD SPECIFICATION FOR ELECTRICAL MOTOR ACTUATED Sheet [12] of | 12 VALVES Seger ex are aear wate a fre AEE. Revo wetter geo 29-6-2012 TWorgieProcton Syatan Test AVL Correctness of ame plte “Submission oF cerifiates | Cerificate From Teslig apeney 1 > Wane tear lite prototype report ATEXCTMFREASEEFAFU/UL?TO | per medel | + Relownt ete for sitolity in specified 1s/ee hezaedou rea standorés T.ertiticate of fire proofing st + 159934 explicable TIL Test for motors as per relevant TS/IEC standard efel . IV.Type test certificates for rotors, V.A ald BIS lene for indigenous sxpply ViStatutery approval certificate from PESO for use in specified hazardous area Vixbegree of protection certificate os eppliable VEELif cycle test report Review of palong and pacing | + Vso 100% fist + Carrelotion of each item con packing fist with box tog runber W «| Tssue of Trapection Release | Peo — Lo Neve Bae ete Notes: i Calibration certificates of al instruments used in performance testing to be submitted Accuracy of the test or measuring instrument to be atleaset 2 times better than the instrument/part being tested, * IRN to be scanned and sent in soft ‘Copy to MRPL prior to dispatch of material. Abbreviations; PESO: Petroleum Explosive Safety Organization R:Review H:HoldPEG pol eer cere Sheet Vay G ew Nos | a i Flanges ra (00-£5-860-605 WyJo}aon Prepared | Checked | Approved by by by a gare | 3 earn | a gare — ARR _| ser | arte | | Description faaxorFLANGES Sheet Pore | Rev, WEE RIOOS Wakon 1.0 GENERAL, 1 All times, their dimensions, tolerances, chemical composition, physical properties, heat treatment and (esting ete. shall conform to the codes and standards specified in the requisition, Deviations, if any, shall be clearly highlighted on a separate sheet by the vendor in the quotation itself, 1.2.1 Test Reports shall be supplied for all mandatory tests as per the relevant material specifications, “Test report sshall also be furnished for any supplementary tests as specified in the requisition & Cl, 1,11, Cl. L12 & Ch. 14, 122 Material Test Certificates (physical property, chemical composition and heat treatment repor() shall also be furnished for the flanges supplied, (3 Ends of weld neck flanges shall be bevelled to suit the schedule / thickness of matching pipe, as specified in the requisition, 14 Bevel end details for welding neck flanges shall be as per ANSI B16,25, The contour of bevel end shall be as follows: Wall thickness Weld Contour Carbon Steed Upto 22 MM. Figure 2 Type A (except low tem, carbon steel) > 22MM, Figure 3 type A. Alloy Stee! Upto 10MM, Figure 4 Stainless and > 10MM &upt25MM Figure 5 ‘Type A Low temp. carbon > 25 MM, Figure 6 Type A Steel, eee 1.5 Bore of socket weld flanges and reducing blind flanges shall suit the outside diameter and schedule / thickness of matching pipe. 1.6 Bow of stip on flanges shal suit the outside diameter of matching pipe. 1.7 Hlange face finish shall be normally specified in the requisition as serrated finish, 125 AARH eto, The interpretation for range of face finish shall be as follows: Serrated Finish + Serrations with 250 to 500 ARH, 125 AARH Serrations with 125 to 200 AARH 63 AARH, + 32063 ARH, (Cae A ca gb >PLANGES [Sheet 3 of6 Rev, sis 00-25-800-005 Libs (9}9) 200 Lio 12 13 Lat 1.14.2 1143 TT Galvanized flanges shall be coated with Zine by Hot dip process conforming to 184736 / ASTM A 153 or by Electtogalvanising, Threaded protion shall be suitably protected during galvanizing, Ends of sorevved flanges unless otherwise specified shall have taper threads as per ANSTB 2.1 (upto 1.5 in NB) and IS : 554 (for 2 in to 6 In. NB), For ring joint flanges, blinds and spacers the hardaess shall be as follows: Flange Materiat Min, Hardness of Groove (BIN) ‘Carbon Steel 140 1% Cr. to 5%Cr, 150 ‘Type 304, 316, 347 160 Type 304L, 316L 140 For ring joint Manges, blinds and spacers, the hardness shall be recorded on the lest report, Flanges, blinds, drip rings under “NACE” category shall meet the requirements of ‘specified in the * Standard Specification for sour service Piping * All austenitic stainless steel flanges shall be supplied in solution annealed condition, For all austenitic stainless stcel flanges, blinds, drip rings and Fig flanges tergranuilar corrosion test shell have to be conducted as per following: ~ ASTM A 262 practice ‘B’ with acceptance criteria of “60 mils/year (max.)" oR + ASTM A 262 practice “B? with acceptance criteria of “no racks as observed from 20 X magnification” and “Microscopic structure to be observed from 250 X Magnification”, When specifically asked for high temperature application of some grades of uustenitic stainless steel (like $S 309, 310, 316, 316H etc.) ASTM A 262 practice ‘C’ with acceptance eriteria of “15 Mits/year” shall have to be conducted. For the IGC Test as described in 1.14.1 and 1.14.2, two sets of somples shall be drawn from each solution treatment lot, one set corresponding to highest enrbon content and other set conesponding (o the highest rating / thickness, ican rags DOE —FLANGES fe [ Sheet 406 Rev "00-88-800-005 WSR 22 3.0 al 32 33 34 35 36 37 Flanges coming wnder the purview of IBR_ (Indian Boiler Regulations) shall be accompanied with IBR Certificate in Form fil C duly approved and countersigned by IBR Authority / Local Authority empowered by Central Boiler Boatd of India, For carbon steel flanges described as “IBR", Chemical composition shall conform to the follon Carbon (Max) 0.25% Olhers (S,P, Mn) As presetibed in IBR Regulation, ‘The chemical composition as indicated in this Ctause is not applicable for flanges other than IBR. ‘Marketing and Despatch All items shall be legibly and conspicusoly stamped in accordance with the requitemnents of applicable ANSI, API and MSS standards, MRPL Code, Purchase Order No, & Special Conditions like “IBR®, CRYO", “NACE” ete, shall also be stamped, All ems coming under the purview of “IBR", “CRYO” & “NACE” shall be painted in Red strips, Light purple strips & canary yellow strips (25MM. width) respectively for easy identification. Paiut or ink for marking shall not contain any harmful metal or metal salts such as zine, lead or copper which cause corrosive attack on heating, tems shall be dry, clean and fice from moisture, dirt and loose foreign ‘materials of any kind, All itoms shall be protected fom rust, corrosion and mechanical damage during transportation, shipment and storage Rust preventive on machines surfaces to be welded shall be easily removable with petroleum solvent, and the same shall not be harmful to welding, Bach encl of flange shall be protected with the following materials: Flange face + Wood, Metal or Plastic cover Beveled end + Wood, metal or plastic cover, ERA STA NORD ein Beings DOE ;FLANGES: Sheet 5 of 6 Rev3, 00-5S-800-008 (9psfzow ‘Threaded end 1 Plastic plug Socket welding end: Plastic cover or plug 3.8 Exch size of flanges, blinds etc, shall be supplied in separate packagings marked withthe Purehase Order No em, code no,, material specification, size and rating. 40 All certification / records required as per the standatd shall be supplied slong with the material itself Non- compliance of this may lead to material rejection after receipt, RISURWINAVSTANDRDS peciietion tr tanger DOCSheet GG "00-ES-800-005 [A [approval Ht [Hold W [Witness [1 information —— Px submie 1 4, "Witness inspection and/or document review by MiNPL/TDL Witnoss inspection by Vendor/5ub vendor a = 3._|Centcaes and Oat tobe submitted by ver Yor Approval/Revaw by TPUAAR Detaled Inspection and Test Plan & Quality Assurance plan after ious of ese oder. Inspection and eat Protedues including HDT recedes : ‘Packing Procedure/Shipping Drawing/Detals a aw Material inspection and identiteaton = Heat Treatment records and charts ca Stamping of Samples for testing(samples/per heat/per heattreatment/per size/per srating,ete) oe ‘Mechanical esting forthe Tolwing tes 1Tensile test 2.lmpact test{if applicable) 3.1GC and any other test{if: applicable) ‘4Mlardaess check on samples S.Any other applcablefmentioned tests HH X_ | Product chemical Analysis x [sor ia X_ | Final inspection Vial bin Tr He z H H Marking or stamping check/Review of manufacturer's certificates and aa Stamping/Review of statutory certificates if applicable it | / WJ pa for stainless Steet and Ay Sol anges, eceereLs} /W [x | Packing and shipping as per stardacd : x SS ceeeeereeer afi (a3 fir [in PT stamping andissue of inspection Release Cancale g = sional ,etc}-100% by vendor and random (note 3) by Notes: 3 This is ust an idieative pion and! the detalled test plan and QAP tobe submitted to MRPL for approval 2,Avhevcover Statutes ke 1BR/Petzoleum Rules/SMPV rules etc are applicable the same news re sey lowed without deviation and supply shall be made along with relevant certileates The exe shall be reflected in the QAP submiited to MAPL for approval, 3.Random sholl be defined as follows: Random Inspection By TPi(for each size and type]oriole a VALVES Sheet Tof ii Revd aT TAOS, Tos [ 5.3.1 and 5.3.2 revised MVK 3] 3/2107 | Requirement of Gear operation MVK modified. Para 7.2 modified Baitorial Changes 2 [25/105 {9.1 modified to include | CS MVK [reference fo MR-0103 Tf aaTtof57 | stan ncorporated ‘0 24703/97 [Issued as standavd MVK Vor Roy [Date [Description Made by ‘ApprovedHH ‘VALVES ‘Sheet 2 of 1 Revd OES TiO Qat 212 2S 216 2D 22 GENERAL Vendor shall supply valves in accordance with tho valve specification shees slong with auxiticies, If any, such as gear operator, bypasses, rains eto, wherover specified in the specification sheets, subject notes and other enclosures to the requisition, Vendor shall quote in stiiet accordance with the valve data / specification shots, subject technical notes aud all other enclosures to the requisition. ‘Deviations to the spec / dala sheets, subject technical notes and other encloses of the requisition, If ‘any, shall be asked as explained in Clause 2.0, All codes and standards for manufacture, testing, inspection ete., shall be of atest editions, DOCUMENTATION: ‘Vendor shall submit with the offer the follow Manufacturer's complete descriptive and illustrative catalogue / erature, Delaited dimensioned, cross section drawing with parts / material lists, weight te, for the ball, plug, buttery valves, diaphragm valves nud valves to manufyctuter's standard, Drawings for valves with acessories tike gear operator, extension bounet, extended stems withstands bypass etc giving major salient dimers One copy of the vaive specification sheets signed as “accepted” by the manufacturer With all deviations marked cleay, IF the valve is regretted or has no deviation, the manufacturer shall waite clearly on valve specification sheeis as “regret” or “no deviation? For subject notes, if there is any deviation, the same shall be listed clause wise, even lnuses which are nceeptable shal be categorically confirmed as “accepted” Failure to submit documents as specified in clauses 2.1 to 2.1.6 above, the offer Is likely (0 be rejected, ‘Vendor shall submit for approval drawings mentioned in item No.2.1.2.& 2.1.3 ater Placement of orders and before start of manufacture. No other drawing shall be “submited for approval,23 24 32 33 a4 as VALVES ‘Test Reports shall be supplid fra mandatory tests a8 ber the applicable code, ‘Test alae s ign M80 be furnished for any supplemeniny tests as spetineg clause 3.13, Material Test Certicstes (physical yropenty, chemical composition and heat {reanentseport shall also be fished forte valves supped, DESIGN AND CONSTRUCTION: Nalves shall bo designed, manufactured, tested, inspected and marked as per the ‘rapufacturing standards design codes and standards (latest editions) indicated in the respective valve specification sheots, enclosures, specification sheets and referred 2 Notice ofthe purchaser for claeifiat page alstion including subject notes shall govern. Ne dente’ ‘0 specification ‘ads shall be permited through vendor deaving approval Approval of draw shall be valid only for design features, Cane extenslon wherever speciid In the valve sheet to BS? 6364 shall be for “Ne Gold Box Application” untess otherwise specified ia tne Fequisition, Bven if» ale for In valve sheet, valves indicated as "Cayo" shy ‘snpplied with bonnet extension, For heavy valves provision shall be availble for ting by Way of lugs, eye bolts and ‘such standard devices, uslanged valves shall have flanges integral (uless otherwise stated) with the valve soeh-Melded-on anges are not accepable: Mange fick an be serrated finish Rapele $00 AARH or 125 AARIT (125 AARH Mon) eee AARH (32 to 63 ARK), Forall butt weld end valves with bevel ends per ANSIBU6.25, ‘The contour of bevel shall be as follow MATERIAL WALL THICKNESS Weld contour __ Caan See UR Type A (except low temp, >22.MM Figwwe3 Type A ‘carbon steo)), Alloy steel, Upto 10 Mit Figured Stainless steet > 10MM to 25 MM, Figure $ Type A & Low temp, carbon > 25MM. Figure 6 Type A Steel,VALVES Sheet fofii Revd [ wAsTeaT TBO) 37 38 3.81 3.8.2 383 3.84 39 3.10 312 313, ‘All check valves 3” and above shall have a drain boss at location *G (refer Fig.No.t Of ANSI B 16.34). A tapped drain hole with plug shall be provided as per ANSI B 16.34, {fan overlay weld-depostis used for the body seat ring, seating surfice, the seat ring ‘base material shall be atleast equal to the corrosion resistance of the matelal of the shell By-pass: By-pass requirement for gate valves shall be as follows, unless otherwise indicated in datasheet ANSI 150 Class on sizes 26” and above. ANSI 300 Class on sizes 16” and above, ANSI 600 Class on sizes 6" and above, ANSI 900 Class om sizes 4* and above. ANSI 1500 Class on sizes 4” and above, ANSI 2500 Class on sizes 3” and ubove. 'By-pass valve shall be of globe valve. ‘The valve speclfication sheet » bbypass valve fs given in annexwe I, the sizes shall be as under: On main valve <4" or “4” = On main valve> 4” But< 10" 3/4" On main valve= 10" or> 10" =I" Vendor shall supply the by-pass valve duly tested and fited to the main valve. Valves with by-pass, shall have the direction of How marked ou te main valve, By pass attachment to the main valve body shall not be sorewed, Al fillet welds for by- ass Installation shall bo 100% exumined by DP/MP Test “The bypass piping arrangement shall be such that clearance between main valve body ‘aud bypass assembly shall be the minimum possible for layout reasons. Valve body / bonnet stall be forged / cast as specified. Forging are acceptable in place of casting bt not vice-versa. Material of construction of yoke shall be mininum equivalent to body Bonnet naterial ‘Stem shall be foxged or machined from a forged rolled bat, No casting is permitted. However, integral stem of cast stainless steel ball valve is acceptable. ‘Stellting / hard facing by deposition, shall be eulnlmumn 1,6 mn thiek each, Cryo Service Vaiveat VALVES Sheet Sofi Revd = HES HOO-OOT TOO 3.13.2 3.13.3 34 3.16 307 37 3072. 3.173 3.174 ATS ryo! valves shall be subjected to ene tests per BS 6364 and tea shall be witnessed and cetifet by thi party peetion agency. ‘The vendor has to submit Test Certificate for prottype valves slong wit tie offer, Prototype test eatied oma particular size ofthe samc rating ahd design, ‘Ciyo! service shall pact welding procedure for austenitic staintess steel valves i ‘qualified for impact test as per ANSI B3L,3, Minimum aceeptabl energy shall be 20) or lateral expansion of 0,381 al emp, of 196 Deg, C, Wherever Impact Test of $$ Studs / Nuts i called for Inthe data shes, the Impact valve shall be 275 at the intended service temperature speelMed in the datasheet Valves under “NACE” should follow the requirements given in “Requirements for speeltie corrosive environment”, Austenltle stainless steel valves shall undergo Infergrantilar Corrosion Test (IGC) to ASTM A 262 practice ‘Band acceptance eriteria shall be that corrosion rate shat! tnot exceed 48 mils per year, Two sets of the samples shall be dravvn from each heat lot, one set comesponiting to highest carbon content and other set ding to highest rating, Spiral wound bonnet gasket are to be provided with inner / outer ring except when encapsulated gaskets type body-bomaet joints are employed, Ball plug / butterfly valves: As per prequalification, Fie Sufe Test as per API - 607 / APL GPA / BS 6755 Part It shall be eatied on soft seated bal, plug, buttery valves and also on lubricated ph Valves. ‘The test shall be witnessed ad certified by thied party inspection agency. ‘The vendor has to submit Test Certifete for the paticufar design of the valve offered. Bach valve shall be supplied with a lever / wrench except for gear operated / motor ‘operated valves, Flre safe ball valves shall be supplied with aisatlc devices, BW / SW end ball valves shal have « LOOM fong seamless pipe nipple (compatible {0 body materi!) welded to cach end ofthe valve, Nipples are to be welded prior to assembling Teflon seals / seals, Schedule of nipple shall be indiened inthe valve specification sheet, Pace to face dimensions of al ball valves shall be same as those of gate valves of the sconresponding ANSI Class (except 12" onward ln ofass 150 where dimensions shall be as per API 6D fong pattern).oe ‘VALVES ‘Sheet Gofir Revd Hil ase aT STD 3.17.6. The ball ofthe ball valve shall nt protrude out ouside the end flanges of valve, 3:17.7 Ball valves shall bs floating ball type /ranion mounted type as per following: 1508 Pk below Floating ball Beer 10" & above ‘Trunion Mounted 3008 4" & below Floating ball 6" & above ‘Trunion mounted oo 1.5” & below Ploating bal Baboye __2”& above ‘Twunlon mounted, — 4. OPERATION: ‘41 Generally the valves are hand wheel or fever operated, Gear operation shall be provided as unde, unless specified othenvise inthe individual valve data sheets Valve Type Class ‘Size vequiting Gear-Oper Gate Valve 150 Class 12 and tg. & dlapinagm, 300 Class 12" and Inger 600 Class. 12” and larger, 900 Class 6” and larger. 1500 Class ‘and larger, 2500 Class 3" and Inger. ‘Globe valve 900 Class. 6" ond larger: 1500 Chss Yd lager 2500 Class and larger Ball Plug 150.Clss 6 and large. Valve (her 300 Class 6 ned lng. the pressure 600 Cinss 4" and ingen Bainnce plug 900 Class, 3” and lager _valye) 1500 Class Standage ‘12. For pressure balanced plug valves the gear operator shall be as per manufacturers For sizes lower thon these ranges, had wheel / lever / wrench shall 49 Gear operator shal be es wader wlth position indleators for open / close positions, Limit stops shall be provided for'quarter turned valves, For Gate /Glove Valve/ Diaphragm + Total enclosed Bovel Gear in44 4S 16 47 5.1 52 53 53. 53.2 recy 2tnP TARO a CS VALVES ‘Sheet Tofir Revd Grease case with grease nipples For Ball / Plug / Butterfly Valve ‘Totally euclosed helical worm gear In grease case, with grease nipples Where gear operator isnot called foras per elause 4.1 but vendor recommends a gear operator, he shall highlight such ease(s) and quote separate prices for the valve and ‘gear operator, Gear operitor shall be so designed to operate effectively withthe differential pressure ‘cross the closed valve equal (othe eold non-shook pressure rating, ‘and Butterfly valves even with wrench or lever operators shall have ‘position indicators with lint stops. Hand whee! diameter shal not exceed 750 mm and fever length shall wot exceed S00 tmnt and effort to operate shall not exceed 35 kg al hand wheel periptery., However failhig to meet the above requirements vendor shall offer gear operated valve oad quote as percluse 4.3, INSPECTION AND TESTING Itory tests and checks called in the Bvery valve shall be subjected to all the n respective codes / data sheet Every valve, ifs components and auxilintes be subjected to all the mandatory (esis ‘and checks called inthe respective coues, data sheets eto. by the mannfacta ‘The extent of third party / owner inspection shall be as follows: Forged Valves: ‘Visual and dimensional inspection Review of material test certificates Any mandatory or supplementary test-review of records. Witness liydrostatle test on 10% valves (or minimum 5 nombers for each size ‘and spec) selected on random basis, Review records for balance Sip check is required for 196 of total ordered quantity of valves (min 1 no) {or any Stainless Steel, Alloy Steel or valves meant for special service (like Sulphuric acid service) oras mentioned tn the hiividual data sheet, * 10% of ordered quantity of gate valves (mninimum 5 nos ofeach size and spec fo be checked for satisfactory operation, Gate opening should be 100%. Cast steel Valves: + Visual and dimensional inspectionVALVES Sheet Fort] Reva aS 66 G0T 911172008. 5. 4 $8 56 57 58 Revlew of Matec test eentitieates + Review of Radiographs / Radlographle reports or any otter NDT tests ‘wherever applicable as pr data shee, 4+ Any mandatory or supplementary test~ review of records, + Hyetrostalle test — Witness 100% for body, 10% other tests (mn for each sae and pee). Review records for balance 4+ Strip cheok is vequited for 1% of total ordered quaitiy of valves (nin | no.) for any Stainless Steel, Alloy Steel or valves meant for special service (like Sulphutie acd service) oF as mentioned in the individual datasheet. Samples for strip check shall be selected at random and shall generally be In the highest size in the ol. + 10% of ordered quantity of gte valves (minimum 5 n0s of euch size and spee )1o be cecked forsalistictory operation, Gate opening should be 100%. imum S nos 1h case of motor operated or setuator operated valves, finctional/ operational checks as per the requlrements ofthe spectffentions shall be made on each valve. Valves unvder eritcal, very highly critical, lethal and toxic services. shall be radiotephed as specified tn respective dota sheets. When specifically not lin individual data sheets, valve castings shall undergo radiographic exa specified heremnder: Materint Rating Size Range Radiography All 150# 24” und below Nid 150# 26" and above 100% 300% 16" and below Nil 3008 18" and above 100% ‘6008 and above. Allsizes 100% Radiography procedure, areas of casting {0 be radiographed shall be as per ANSI 16.34 and acceptance criteria shall be as per ANSI B 16.34 Annexue-B. However for areas of casting to be radiographed for typos of valve not covered in ANSI B 16.34, vendor shall enclose details of areas (0 be radiographed in line with ANSI B 1634. Random radiography wherever specified in individual data sheets the sampling s all ‘be per size of the quantity ordered for each foundry. Radiography wherever specified in the data sheets or as per clause 6.1 shall be dane by X-tay / Yo1ay (o get the required sensitivity,a VALVES ‘Sheet Dorie a tee oS ATHOT TLE iN y Revd 61 62 63 64 a uM 18 16 aL 82 IBR CERTIFICATION For valve described “IBR®, valves shall be in accordance with the ttest IBR (Indian Boiler Regulation) including the requlrements specified inthe specification, SW _/ BW end carbon steel valves under IBR, the chemical composition shall ‘conform tothe following: ‘Carbon (Max.) 0.25% Others (S.P.Mn) 5 Asper BR re ulations ‘The above composition isnot valid for Non-IBR valves, For vaives described “IBR® test certificate Inform I1-C shall be furnished, signed by {BR inspection authority or an approved representative. All “IBR” valves shal be pointed Red MARKING Valve makings, symbols, abbreviations eto, shall be in accordance with MSS-SP-25 or the stondard referred in specification sheet as applicable, Vendor's navn, Valve rating, material designation, nominal size, direction of flow (if any) ete, shall be integral on the body. Lach valve shall have a corrosion resistant tag giving size, valve specification sheet mber securely attached on the valve body, ny harmful metal or metal salts such as Paint oF ink for marking shall not cor altack on heating Zino, lead or copper which causes com Carbon steel valves shall be palnted with two coats of Red Oxide Zine Chromate primer, All alloy steel high temperature valves shall be painted with heat resistant silicone plot sultable for Intended temperature. All3 -1/2% Ni Steel /LTCS valves shall be painted with paint suitable for tow temp. DESPATCH Valves shall be dry, clean and free fiom moisture, dit and loose foreign materlals of any kind, Valves shall be protected From rust, corrosion and any mechanical damage during transportation, shipment and storege,VALVES Sheet [ot Reva ein fils SANT ‘wri T72005, 8.3 Rus preventive on machined surfers fo be welded shal be easly removable with a peiralemn solvent or nt hanna to welding. 84 nd of valves sal be protected with th following mates: Plage face Wood, metal oF paste cover Bevelled end A Wood, metal or plastle cover Wand scrowedend —:—_Plsliceap 85 End protestors to be used on flange feces shall be attached by a evs three bolls. oF wiring through bolt holes and shall not be smaller than the outside diameter of he flange, However plastic caps for SW and screwed end valves shall be press fit type. 8.6 Bnd protectors to be used on beveled end shall be seourely and tightly attached, 4:7 For speclal service valves additonal requirement of dispatch shall be presribed in daa sheet 8.8 All certification / records required as per the stondard shall be supplied along with the 9.1 92 9.2.1 imateriat itself, Non-compliance ofthis may lead to material rejection after recelpt, ‘SPECIAL REQUIREMENTS. ‘This sectlon covers the miaimom requirements for material, fabrication and testing of ‘material in spectfic environment as listed below. Wet Hydvogen Sulphide (H 28 resistant material) Material shall confora to NACE MR-0103-2003. The maximum hardness of heat affected zone after PWHT shall be less than 225 BHN. Hantness of forged aud east components requiting resistance to Hydrogen Induced Ciacing in Wet H2S environment shall have hardness limited o 225 DEIN.‘VALVES Sheet Toft Revd wEFOAOT aio BYPASS VALVE SPECITICATION Type, TINGS SHEET SHEET NUMBER fen S1301X, SMOIX, | APISE GRB ‘105, Sw, 6oo0H | $2001X 51404X. SEAMLESS $160, H a 51503X, 51403, | A333 ORB ‘A350 GRLP2, SW] 52003X S1303K. SEAMLESS sso |3000/ 51302X, S1402X | A 106 GRB, S8OIBR | A105, SW 30008 TDR | 52002x SISTIX, STATI, [APTSL ORB ‘Ai0s, SW 5000 | S2011K SI3L1M. SEAMLESS, SCHXXS ‘S1336X, ST436X TABISORPSSIO [A 182 GR FS SW|S2036X ‘co0od S1502X ‘A106 GRB, SSO TBR A105, SW, 3000MBR_ | s2072X_— ‘s1527X ‘A335 GR PI A 1e2 “GRE SW/S2027x SEAMLESS $80, 15R_|3000# IB 51531 ‘A335 ORPLL ‘Al82_GR FIT, SW] 52031X SEAMLESS $80 1BR__ } 30008 IBR 51339X, SUA39X, [A395 GR PD ‘A 182 Gk FY SW] 52039K 51530 SEAMLESS $160___| 60008 ‘S1313X, S1413K | APISL GRD ‘A 105, SW 900087 | $2001X SBAMLESS, SCH XXS S1701X ‘APISL GRB. ‘ADA WEBTATOS BW | 52101 SEAMLESS S160_| S160 31702K APISL GRB, IBR ‘Az34 WEB / A105 BW | S2102K SEAMLESS SCH160__| S1601BR SITBIX ‘A33SORPITIBR | A234 WPII/AI&2 GR | 52131 SEAMLESS S160___| FI BW S160 1BR |ungeufis pue dureis s opus, 48YO 247 UIA Buoy Jarmecivose pepe | a San a 31 84 wos Avo 94 eS Touebe ueRssdsu] ens Pue uBisctweisIN, Buessewuo} sy dn oy ©1 1opuan'suojeinap ou L 224WON ueWiNsog sousreyoy StEIeg UoHeMag ONIS SSQMINN (ues Blog a1e SjueUWOD Yorym Yohusuno0g sopuen QUINN soUsiajey J9B10 HOM sopuey = ona] [ewaunasg ae ovo _ a 3eWOY UoReinag ! 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