Technical Specification

DOUBLE BLOCK & BLEED AND DOUBLE ISOLATION VALVES
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Chapter 9

Specifications for Double Block & BleedAnd
Double Isolation Valves


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INDEX

A) TECHNICAL SPECIFICATIONS : DOUBLE BLOCK & BLEED AND DOUBLE
ISOLATION VALVES

1.0 SCOPE

2.0 APPLICABLE CODES, SPECIFICATIONS & STANDARDS

3.0 GENERAL FEATURES / SPECIFICATIONS

4.0 DESIGN DETAILS

5.0 QUALITY CONTROL / INSPECTION & TESTING

6.0 DOCUMENTATION

7.0 MARKING

8.0 PAINTING / PREPARATION FOR SHIPMENT

9.0 SPARES & SPECIAL TOOLS

10.0 WARRANTIES


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B) TECHNICAL SPECIFICATIONS : FLAME PROOF ACTUATORS

1.0 SCOPE

2.0 CODES & STANDARDS

3.0 GENERAL REQUIREMENTS

4.0 TECHNICAL SPECIFICATIONS

5.0 REQUIREMENTS OF HAZARDOUS AREAS

6.0 INSPECTION , TESTING AND ACCEPTANCE

7.0 PACKING AND DISPATCH

8.0 SPARES & SPECIAL TOOLS

9.0 WARRANTIES

11.0 DATA SHEET FOR MOV ACTUATORS- PURCHASORS DATA

12.0 DATA SHEET FOR MOV ACTUATORS- MANUFACTURERESSS DATA

ANNEXURE A : QUALITY ASSURANCE PLANS


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A) TECHNICAL SPECIFICATIONS : DOUBLE BLOCK & BLEEDAND DOUBLE
ISOLATIONVALVES

1.0 SCOPE :

This specification establishes the technical requirements for Double block & bleed and
doubleIsolation valves with single operatorto beused for positive isolation in Oil
Installations, handling refined petroleum liquid hydrocarbon products(
MS,SKO,HSD,NAPHTHA and ATF.

The Size and pressure rating of valves required shall be as per BOQ(Bill of quantities) of
the tender document. The valve shall be conforming to API-6D specifications & shall
bear API-6D monogram.

This specification covers the minimum requirements for the design, manufacture,
Assembly, Inspection, testing, certification & delivery of Manual / electrically operated
Double block & bleed and double Isolation valves complete with all
accessories.Specifications of electrical actuators is covered in section B of this document.

2.0 Applicable Codes, Specifications and Standards:

2.1 Applicable Codes & standards

2.1.1 The design, manufacture, assembly, inspection, testing and certification of
Double block & bleed and double isolation valves shall be in accordance with
the latest edition of the codes& standards including amendments as mentioned in
the tender specifications. Some of the standards have been listed below for ready
reference :

API-6D Specifications of Pipeline valves

API-6FA Specification for Fire test for Valves.

API-598 Valve Inspection and Testing

ASME B1.20.1 Pipe Threads, General Purpose (inch)

ASME B16.5 Steel Pipe Flanges and Flanged Fittings

ASME B16.10 Face-to-Face and End-to-End Dimensions of Valves
ASME B16.34 Valves Flanged, Threaded, and Welding End

ASME B31.3 Chemical Plant and Petroleum Refinery Piping


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ASME B31.4

Liquid transportation systems for hydrocarbons and
other liquids

ANSI B46.1 Surface Texture (Surface Roughness, Waviness & Lay)

BS EN 12266 Industrial Valves, Testing of valves, test procedures &
acceptance criteria.

BS-EN 102222 Specification for steel forgings for pressure purposes
BS-EN 10213 Specification for steel castings for pressure purposes.

BS 1560 Steel pipe flanges and flanged fittings.

BS-EN 1092 Flanges and their Joints-Circular flanges for pipes, valves, fittings
and accessories, PN designated.

BS-EN 1515-1 Flanges and their Joints.

BS 5146 Inspection and test of steel valves for the petroleum, petrochemical
& allied Industries

MSS-SP-6 Standard finishes for contact faces of pipe flanges and connecting
end flanges of valves and fittings
MSS-SP-25 Standard marking system for valves, fittings, flanges and unions.

MSS-SP-44 Steel pipeline flanges.

MSS-SP-45 By-pass and drain connection standard
MSS-SP-61 Pressure Testing of Steel Valves

MSS-SP 55 Quality standard for steel castings-visual method.

MSS-SP 61 Hydrostatic testing of steel-valves.

2.2 Deviations to specifications :

2.2.1 The Bidder shall provide an itemized list of any deviations to this
specification.Theseshall be listed on the Compliance sheet with seal & duly
signed by authorized signatory & shall be submitted along with offer by the
Bidder.

2.2.2 Where a conflict between standards occurs then the Bidder shall seek a
clarificationruling from the Owner. Where a deviation from the standard is


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required, then theBidder shall make a formal request with full supporting
information.

2.2.3 Only those deviations that are agreed between the Owner and the Bidder will be
Incorporated into the requisition at the time of order.

2.3 Conflicting Requirements :
In case of conflict between the requirements of this specification, API 6-D and the
Codes, Standards and Specifications referred in clause 2.1 above, the
requirements of this specification shall govern. Order of precedence shall be as
follows:

First priority - This Specification

Second priority - API 6-D/6FA

Third priority - Other Referred Codes & Standards

Fourth priority - Manufacturers Standard

Note: Should any conflict arise either before or after order placement the Bidder
shall immediately inform the Owner for technical resolution of the conflict.

2.4 Abbreviations & Terminology :

CE Carbon Equivalent
FAT Factory Acceptance Test

POL Petroleum, Oil Installations of Oil Companies

MOV Motor operated valve
HOV Hand operated valve
QAP Quality Assurance plan
PESO Petroleum & Explosives Safety Oragnisation, Nagpur, India.

2.5 White Oil Product Details : In the table below, Product Characteristics of the
products in POL terminal are mentioned as general guidelines to bidders

PRODUCT CHARACTERISTICS

Product Flash
Point ( C)
Specific
Gravity
Vapor
pressure
Viscosity
(cST)
Pumping
Temp.(


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(gm/cc) (kg/cma) C)
HSD High
Speed Diesel
> 35 0.82 0.86 < 0.4 2-5 @
40C
Ambient
MS Motor
Spirit
(-) 30 0.73 0.7 < 0.7 Ambient
Naptha (-) 20 0.69-0.78 < 0.7 < 0.7 Ambient
ATF Aviation
Turbine Fuel
> 38 0.8 < 0.4 2.56 Ambient
SKO Super
Kerosene Oil
> 35 0.8 < 0.05 1.97 Ambient

3.0 GENERAL FEATURES / SPECIFICATIONS:

3.1 The valve shall have one operator only. Gear operation (with or
withoutreduction gear) shall be provided as per manufacturers specifications /
relevant standards.

3.2 Gear operator shall be provided with position indicators for open/ close
positions, with limit stops as per manufacturers design in line with API-6D. The
operators shall be totally enclosed of helical worm/bevel or combination of
helical worm, bevel and spur gear in grease case with grease nipples/ plugs or as
per specifications of manufacturers with weather protection.

3.3 Gear operator shall be so designed to operate the valve at break away torque as
defined in API-6D. The maximum force required at the hand-wheel or wrench to
apply the breakaway torque or thrust shall not exceed 360 N (80 lbf). However
failing to meet the above requirements vendor shall offer gear-operated valve and
quote as above.

3.4 Valves with wrench or lever operators shall have open position
Indicators with limit stops.

3.5 Wrenches for valves, if required, shall either be of an integral design or consist
of a head which fits on the stem and is designed to take an extended handle. The
head design shall allow permanent attachment of the extended section if
specified by the purchaser. Wrenches that are of integral design (not loose) shall
not be longer than twice the face-to-face or end-to-end dimension unless
otherwise agreed. Hand-wheel diameter(s) shall not exceed the face-to-face or
end-to-end length of the valve or 1000 mm, whichever is smaller, unless
otherwise agreed. Except for valve sizes DN 40 (NPS 1.) and smaller, spokes
shall not extend beyond the perimeter of the hand-wheel unless otherwise agreed.
If specified by the purchaser, the hand-wheel of the gearbox input shaft shall be


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provided with a torque-limiting device, such as a shear pin, to prevent damage to
the drive train. Direction of closing shall be clockwise, unless otherwise
specified.

3.6 Vendor shall be supplying flame proof / PESO,India approved electrical
actuators along with the valves where ever specified in the BOQ. Actuators of
ROTORK, LIMTORQUE, AUMA makes shall be acceptable for item no.s 1&3
and only Rotork make is acceptable for item no.2. Other makes may be
accepted for item no.s 1&3 who have proven performance worldwide since
previous 3 years from date of NIT & have well equipped maintenance &
service support in India as on the date of NIT. Valve vendors to submit full
details to verify their full credentials including performance certificate from 3
major users in the oil industry.

3.7 The valves shall be Expanding gate valves with rising stem having two piece
parallel expanding gates with resilient seats.The valve shallbe designed to
provide a tightmechanical seal and positive shut-off under high and low
differential Pressures.

3.8 Rotation of the hand wheel/operatorwhile opening shall lift gate without wiping
the seals due to retracting action of the sealing slips so that during lifting of the
gate, clearance is maintained between the sealing slips and the valve body to
minimize wear & tear of the seals. Rotation of the hand wheel/operator while
closing shall lower gate after the sealing slips are aligned with the valve body
and force the sealing slips against the valve body for positive closure
independent of line operating pressure.

3.9 Motor operated valves shall be directly mounted with flame proof electric
actuators /gear operators and delivered to the field as a complete unit.

3.10 RELIEF SYSTEM:The valves are to be provided with integral thermal relief
system consisting of suitable valves & piping as per ratings of the valves to relieve
the pressure build up in the internal body cavity when the valve is closed. Relief
valves shall open at minimum 25 psidifferential pressureor as specified by the
manufacturer within limits as specified under clause 7.8 of API-6D and shall
discharge to the upstream side of the valve. Thermal relief valves shall be
externally placed in a way so that the same can be serviced without
dismantling the main valve.

3.11 BLEED VALVES:Manually operated bleed valves are to be provided on the
valvethat can be opened to verify that the valves are not leaking when in the closed
position. Suitable discharge piping with isolation valves and end plug / suitable
adaptor for extension purpose, shall be provided so that the released liquid from
each bleed valve can be containedlocally. There shall be a provision to provide


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necessary instruments for remote checkingof valve integrity in control room,
if required by the user company.

3.12 Vendor shall quote in strict accordance with the valves data/ specification sheets,
subject technical notes and all other enclosures to the tender document. Any
deviation to be highlighted clearly in the deviation sheets enclosed.

3.13 Vendor shall supply valves along with auxiliaries, if any, such as gear operator,
bypasses, drains etc. wherever specified in the specification sheets, subject notes
and other enclosures to thetender document.

3.14 Valve body shall preferably have provision to drain any muck or dirt remains
inside the Valve body, which can damage the seats. The wetted parts of the valve
will be exposed to the particulate matter (of the size less than 40 mesh) along with
the process fluid which the proposed valves to handle. The particulate matter will
be ferrous particles, mill scale, corrosion deposits etc. Hence, manufacturer shall
select proper MOC (material of construction) of parts which can withstand to the
abrasion, scouring etc. due to the presence particulate matter in the process fluid.
The selection of MOC is the sole responsibility of the vendor even though the
minimum requirement is mentioned in clause no.4.28

3.15 The valve bodies shall be suitable for above ground open atmosphere
Installation& shall be suitable for ambient Temperature range of-10C to + 55C&
Relative humidity up to 100 %.

3.16 The valve shall be maintainable while being in position either by unbolting from
Top or bottom or both. Valve design shall permit sealing slips to be replaced from
the Top or bottom with the valve mounted in the piping. Vendor to mention the
clearance required below the valve for on-line maintenance.

4.0 DESIGN DETAILS :

4.1 Valve shall be designed, manufactured, tested, inspected as per API-6D/ISO 14313,
ASME B16.34&other manufacturingstandards,design codes and standards (latest
editions) indicated in latest edition of API-6D .Each valve shall bear API-6D
monogram.

4.2 Metallic Pressure-containing and pressure controlling parts, including bolting,
shall be designed with materials as per manufacturers standards complying with
minimum requirements as stipulated in clause 8 of API-6D.

All process-wetted parts, metallic and non-metallic, and lubricants shall be suitable for the
commissioning fluids and service specified by the purchaser. Metallic Materials
shall be selected so as to avoid corrosion and galling, which would impair function
and/or pressure containing capability. Selection of elastomeric materials for valves


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intended for hydrocarbon gas service at pressures of PN 100 (class 600) and above
shall consider the effect of explosive decompression.

The wetted parts shall be suitable coated with chrome coating / plating, Fluorocarbon coating
& electro less nickel coating as required to enhance properties of materials for
achieving longer life as per manufacturers standards & Approved QAP.

Design and calculations for pressure-containing elements shall be in accordance
with an internationally recognized design code or standard with consideration for
pipe loads, operating forces, etc. The choice of standard shall be in line with API-
6D. Pressure & temperature ratings for ASME class-rated valves shall be in
accordance with the applicable rating table for the appropriate material group in
ASME B16.34. Material of construction of critical components of valves has
been tabulated in Annexure-I.

4.3 Face-to-Face and end-to-end dimensions of valves shall be in accordance
with Tables 2 to 6 of API-6D. Face-to-face and end-to-end dimensions for valve
sizes not specified in Tables 2 to 6 shall be in accordance with ASME B16.10.
Valve connections shall be ASME B16.5, Class 150 or Class 300, raised face
flanged, as specified.

4.4 Positioning of cover must be provided to ensure correct Alignment of the valve
discpart or an arrangement of parts for securing a valve in the open and/or closed
position. Locking devices shall be designed to lock the valve in the open and/or
closed position. The position of the obturator shall not be altered by dynamic
forces of the passing flow. Valves fitted with manual or powered actuators shall be
furnished with a visible indicator to show the open andthe closed position of the
obturator.

4.5 Deleted.

4.6 Travel stops shall be provided on the valve and/or operator and they shall locate
the position of the obturatorin the open and closed position. The travel stops shall
not affect the sealing capability of the valve.Misalignment or improper assembly
of components shall be prevented by suitable means, such as a dowel pinor fitting
bolt, which ensures the correct location of manual or powered operators and stem
extensionassemblies.

4.7 The operating levers or handles on valves shall indicate, by their position, whether
the valve is open or closed. The open position shall be indicated when the lever or
handle points in a direction parallel to the flow through the valve. In addition, it
shall be impossible to reverse the indicating position inadvertently during
reassembly of the valve. Suitable marking shall be done on the valve to indicate
flow direction.


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4.8 Welding, including repair welding of pressure-containing and pressure-controlling
parts shall be carried in line with clause 9 of API-6D.

4.9 Valve body/ bonnet shall be forged/ cast as specified. Forgings are acceptable in
place of casting but not vice versa. For expanding gate valves, fabricated body(
using steel plates) is acceptable

4.10 Material of construction of yoke shall be minimum equivalent to body/ bonnet
material.

4.11 Stem shall be forged or machined from forged/ rolled bar. No casting is permitted.

4.12 Graphite material used for stem packing shall be chloride free i.e. leachable
chlorides shall be less than 50 PPM.

4.13 Stelliting/ hard-facing by deposition, if required shall be min.1.6mm or as per
manufacturers specifications.

4.14 Suitable gaskets are to be provided for body bonnet joints as per Manufacturers
specifications in line with the requirement of standards.

4.15 valves shall be supplied with antistatic arrangement as specified in API-6D

4.16 The MOVs are to be installed in an open area and the actuators shall be IP-65. The
testing of complete assemblies of MOVs along with the actuators shall be carried
out by the supplier at his works.

4.17 Deleted.

4.18 For reduced bore valves, Minimum bore size shall be as per API-6D. Reduced-
opening valves with a circular opening through the obturator shall be supplied with
a minimum bore as follows, unless otherwise specified:

valves DN 300 (NPS 12) and below: one size below nominal size of valve with
bore according to Table 1 of API-6D;
Valves DN 350 (NPS 14) to DN 600 (NPS 24): two sizes below nominal size of
valve with bore according to Table 1of API-6D;
Valves above DN 600 (NPS 24): by agreement / as per standards of
manufacture.

Reduced-opening valves with a non-circular opening through the obturator shall be
supplied as per API-6D.

4.19 The valve shall be maintainable on line, without having a need to remove the valve
body from the piping system. Valve seat shall be removable&replaceable without


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removing the valve from the manifold or pipe line. For gate valves, Valve gate,
segment and seat rings shall be removable without removing the valve from the
manifold or pipe line for ease of maintenance.

4.20 Gate design shall be such that it shall expand only in the closed position and
provide a tight mechanical seal. Increases or decreases in line pressure shall not
affect the mechanical sealing.

4.21 The design of stem protector and position indicator must be rugged and
weatherproof. The position indicator shall be sealed at its exit point from the stem
protector using a suitable mechanism. Operators, stem extensions and their
interfaces shall be sealed to prevent ingress of external contaminants and moisture.
Operators and stem extension assemblies shall be provided with a means of
preventing pressure build-up in the mechanism resulting from stem or bonnet seal
leakage.

4.22 Valve stem packing shall be designed for easy on-line maintenance. The stem shall
be of anti blowout design, permitting replacement of the stem seals with the valve
in fully closed position. Valves shall be designed to ensure that the stem does not
eject under any internal pressure condition or if the packing gland components
and/or valve operator mounting components are removed. The stem integrity shall
be ensured as per vendors design.

4.23 Manufacturer of the valve shall ensure bondingof slip seals for
integrity&there shall be established procedures for ensuring QA/QC of the
sealing materials&bonding. Viton material sourced from DUPONT / 3M shall
only be accepted.

4.24 Drain, vent and sealant lines, if required as per design of the valve shall be
provided and shall be extended by means of rigid pipe work, if necessary. The
lines shall be fastened to the valve and/ or extensions and terminate close to the
stem extension top works, by agreement. Drain and vent lines shall :

have a design pressure not less than the rated pressure of the valve on
which they are installed;
be capable of withstanding the hydrostatic shell test pressure of the
valve
be designed in accordance with a recognised design code;
be suitable for blow-down operation, where applicable.

Sealant lines for stem sealant injection, if required shall have a design pressure not
less than the greater of the pipeline valve rated pressure and the injection pressure.
If not specified by the purchaser, the manufacturer shall advise the maximum
injection pressure for the system. The size of the sealant lines shall be by


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agreement. Prior to assembly, the internal bores of sealant lines shall be clean and
free from rust and any foreign particles.

Drain and vent block valves shall be provided, if specified, shall have a rated
pressure not less than the valve on which they are installed and be suitable for
blow-down operation.

Bypass, drain and vent connections and plug entries shall be drilled and threaded
unless otherwise specified / as per manufacturing standards Thread profiles shall
be tapered unless otherwise agreed. Tapered threads shall be capable of providing
a seal and comply with ASME B1.20.1.
If the use of parallel threads is specified, the connection shall have a head section
for trapping and retaining a sealing member suitable for the specified valve
service. Parallel threads shall comply with ISO 228-1. Minimum sizes shall be in
accordance with Table 7 of API-6D.

4.25 The pressure as determined in accordance with clause 7.2 of API-6Dshall be the
maximum pressure differential (MPD) at whichthe valve is required to be opened
by the lever, gearbox or actuator. The manufacturer shall provide the following
data to the purchaser in technical bid:

flow coefficient Cv or Kv;
breakaway thrust or torque for new valve;
maximum allowable stem thrust or torque on the valve and, if applicable,
the maximum allowable inputtorque to the gearbox;
Number of turns for manually operated valves.

4.26 Drive trains:The design thrust or torque for all drive train calculations shall be at
Least two times the breakaway thrust or torque to allow for thrust or torque
increase in service due to infrequent cycling and the adverse effect of debris.
Allowable Tensile stresses in drive train components, including stem extensions,
shall not exceed 67 % of SMYS when delivering the design thrust or torque. Shear,
torsion and bearing stresses shall not exceed the limits specified in ASME Code
Section VIII, Division 2, Part AD-132, except that design stress intensity values,
Sm, shall be 67 % of SMYS. These stress limits do not apply to the components of
rolling-element or other proprietary bearings or high bearing strength capable
materials that are included in the drive train where manufacturer's
recommendations or limits derived from tests and service experience apply. These
limits shall be justified in design documents, if requested.

The drive train shall be designed such that the weakest component isoutside the
Pressure boundary. A strength efficiency factor of 0,75 shall be used for fillet
Welds .

Note If an actuator or operator can deliver a thrust or torque that is


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greater than the design thrust or torque of the drive train, such a
thrust or torque can result in permanent deformation or failure of
drive train Components. Hence careful selection shall be carried out
for actuator.

Deflections of the extended drive train shall not prevent the obturator from
reaching the fully closed or fully open position. For all valves, attention shall be
paid to deflection and strain. Adherence to the allowable stress limits of
Design codes alone might not result in a functionally acceptable design. The
manufacturer shall demonstrate, by calculation or test, that under loads resulting
from design pressure and any defined pipe or external loads, distortion of the
obturator or seat does not impair functionality or sealing.

4.27 Valves of size DN 200 (NPS 8) and larger shall be provided with lifting points.
The manufacturer shall verify suitability of the lifting points. The valve
manufacturer shall verify the suitability of the lifting points for the complete valve
and operator assembly.

4.28 Materials of construction as a minimum for critical valve components shall be as
given below in table A & B

TABLE -A (DBB and double isolation GATE VALVES)

S. No DESCRIPTION SPECIFICATION VENDORS
CONFIRMATION
1 Body ASTM A 516 GR. 70 / ASTM A
216 GR. WCB/WCC

2 Bonnet ASTM A 516 GR. 70 /ASTM A
216 GR. WCB/WCC

3 Bolts/Nuts ASTM A193 Gr B7/ASTM A 194
Gr2H

4
STEM
AISI 4140 (1.5 mm stelliting /
ENP)

6

STEM SEAL
GRAFOIL TYPE TO COMPLY
WITH FIRE SAFE
REQUIREMENT

7

GATE /
SEGMENT

A216WCC/ WCB or ASTM A
516(ENP)

8
SEAT
ASSEMBLY
ASTM A 516-GR.70 OR A105

9 Centralised arm ASTM A 516-GR.70(ENP)


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10

SEAT SEAL

VITON (DUPONT/3M)

11

O-RING SEALS

VITON GFLT

12

PRESSURE
RELEASE
VALVE
SS-316

13 Packing Graphite
14 End Flanges ASTM A 105,125AARH
15 Tubing /
connectors
/check /needle
valves
SS-316

4.26 All applicable codes and standards for design, materials, manufacture, testing, inspection
etc. shall be of latest editions. Vendor to list all the specifications / standards applicable.

5.0 QUALITY CONTROL / INSPECTION & TESTING

5.1 Valve shall be subject to all the tests and checks required as per quality control
requirements of clause 10.0 & testing requirements of clause 11.0 of API-6D &
other relevant standards & as per the QAP specified in the tender document.
However vendor shall submit their detailed QAP in line with the specifications
stipulated in this tender document. NDE tests shall be carried out in line with
Annexure-A of API-6D. Vendor shall be deploying services of TPIA for
witnessing tests as per approved QAP at their (Vendors) cost. Approved TPIA
agencies are:

TUV,
Lloyds,
BureuVeritas,
Certification Engineers India LTD,
Det Norske Veritas,
SGS.

5.2 Purchaser, at its discretion may depute their representatives at their own cost to
witness critical tests at manufacturing works in addition to TPIA.

Chemical composition and mechanical properties shall be checked as per relevant
material standards and this specification, for each heat of steel used.


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Non-destructive examination of individual valve material and components
consisting of, but not limited to castings, forgings, plate and assembly welds shall
be carried out by the Manufacturer in line with API-6D.

5.3The manufacturer shall submit a certificate covering the testing of the valves
andcertifying the materials of construction used in the valves, according to API6D
and other relevant standards of Latest edition.

5.4Vendor shall submittype test certificates for fugitive emission tests carried out in
accordancewith TU-LUFT / ISO 15848 / US Clean air act or equivalent standards.

5.5Valves shall be tested prior to shipment in line with the requirements of API-6D and
agreed QAP. Testing shall be performed in the sequence detailed in API-6D.
Pressure testing shall be carried out before coating of the valves. Test fluid shall be
fresh water or, by agreement, light-weight oil having a viscosity not exceeding that
of water.Water used for testing shall contain a corrosion inhibitor.

5.6 Deleted

5.7Supply pressure shall be stabilized prior to the start of pressure testing and shall be
held for the minimum testdurations listed in Tables 9, 10 and 11 of API-6D.

5.8Fire type-testing certification of the design shall be provided. The fire-resistance
design of valves shall be qualified by fire type-testing in accordance with ISO
10497.Fire resistance designs already qualified to ISO 10497, API 6FA, API 6FC,
API 6FD or API 607 are also acceptable as per stipulations of API-6D.

5.9Hydrostatic shell test:Valve ends shall be closed off and the obturator placed in the
partially open position during the test. Ifspecified by the purchaser, the method of
closing the ends shall permit the transmission of the full-pressureForce acting on the
end blanks to the valve body. If present, external relief valves shall be removed and
theirconnections plugged.The test pressure shall be 1,5 or more times the pressure
rating determined in accordance with 7.2 forMaterial at 38 C (100 F). The duration
shall not be less than that specified in Table 10.No visible leakage is permitted
during the hydrostatic shell test.

After hydrostatic shell testing, external relief valves shall be fitted to the valve. The
connection to the valvebody shall be tested at 95 % of the set pressure of the relief
valve for 2 min for valve sizes up to and includingDN 100 (NPS 4), and 5 min for
valve sizes DN 150 (NPS 6) and larger. The relief-valve connection shall befree of
visible leakage during this period.All the valves are required to be tested for
hydrostatic shell test.

5.10 Hydrostatic seat test: The test pressure for all seat tests shall not be less than 1.1
times the pressure rating determined in accordance with clause 7.2 of API-6D for


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material at 38 C (100 F). The test duration shall be in accordance with Table 11.
The test procedures for various types of block valve shall be in line with para
11.4.4.of API-6D

Acceptance criteria:

Essential requirement: One valve of each size shall be operated with MS
(gasoline) as operating medium for 1500 cycles of operation and then the
same valve shall be subjected to hydrostatic seat test with water as the testing
medium . The result of the test shall comply with the requirements of API 598.

Leakage for soft-seated valves shallcomply with the requirements of API 598.API-
598 states for shell and backseat tests, no visible leakage is permitted. If the fluid is
a liquid, there shall be no visible evidence of drops or wetting of the external
surfaces (no visible leakage through the body, body liner, if any, and body-to-
bonnet joint and no structural damage).

If the test fluid is air or gas, no leakage shall be revealed by the established
detection method. For both the low-pressure closure test and the high-pressure
closure test, visual evidence of leakage through the disk, behind the seat rings, or
past the shaft seals (of valves that have this feature) is not permitted (Plastic
deformation of resilient seats and seals is not considered structural damage).

The allowable rate for leakage of test fluid past the seats, for the duration of the
tests, is listed in the following table:

Valve Size
All
Resilient
Seated
Valves
All Metal-Seated Valves
(except Check Valves)
Metal-Seated
Check Valves
Liquid Test
(drops/min)
Gas Test
(bubbles/min)
Liquid Test
(drops/min)
Gas Test
(bubbles/min)
<= 2" 0 0 (b) 0 (b) (c) (d)
2.5" - 6"" 0 12 24 (c) (d)
8" - 12"" 0 20 40 (c) (d)
>= 14"" 0 28 56 (c) (d)

Where :

(a)1 milliliter is considered equivalent to 16 drops

(b) There shall be no leakage for the minimum specified test duration. For
liquid test, 0 drop means no visible leakage per minimum specified test
duration. For gas test, 0 bubble means less then 1 bubble per minimum


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specifiedtestduration.

(c) The maximum permissible leakage rate shall be 0.18 cubic inch (3 cubic
centimeters) per minute per inch of nominal pipe size.

(d) The maximum permissible leakage rates shall be 1.5 standard cubic feet
(0.042 cubic meter) of gas per hour per inch of nominal pipe size.

All the valves are required to be tested for hydrostatic seat test.

Additional seat testing:

Since the valves are expected to have the functionality for the valve to be that of
double-block-and-bleed (DBB)& double-isolation-and-bleed (DIB-1), the test
described in Clause B.10 & B.11 of API-6D shall be performed. 10 % of the valves
of all sizes & types are required to be tested for Additional seat testing.

5.11Test of thermal relief valve: The external relief valve shall be set and certified to
relieve at the specified pressure either by therelief-valve supplier or the valve
manufacturer for all the valves.

5.12Testing of drain, vent and sealant injection lines, if provided:drain and
ventLines shall be subject to a hydrostatic test withall the valves.

5.13Anti-static testing: The electrical resistance between the obturator and
the Valve body and between the stem/shaft and the valvebody shall be measured
using a direct-current power source not exceeding 12 V. The resistance shall
beMeasured on dry valves before pressure testing and shall not exceed 10 ohm 5
% of the valves of each size & type shall be tested for Anti-static testing.

5.14Torque/thrust functional testing:The maximum torque or thrust required
toOperate gate or plug valves shall be measured at the pressurespecified by the purchaser
for critical valve operations. Thrust and torque testing shall be performed
following hydrostatic shell testing and, if specified, prior to anylow-pressure gas
seat testing.The measured torque or thrust results shall be recorded and shall not
exceed the manufacturers documentedbreakaway torque/thrust. 1 % of the
valves(min.1) of each size & type shall be tested.

5.15Drive train strength test:The test torque shall be the greater of
a) Twice the manufacturer's predicted break-away torque/thrust, or

b) Twice the measured break-away torque/thrust.


19
The test torque shall be applied with obturator blocked for a minimum time
of 1 min.

NOTE :

For gate valves, the thrust can be tensile or compressive,
whichever is the most stringent condition.
The test shall not cause any permanent visible deformation of the drive
train.
1 % of the valves (min.1) of each size & type shall be tested for Drive train
strength test.
.
6.0 DOCUMENTATION :

6.1 Vendor shall arrange to retain documents in his works as stipulated in API-6D.

6.2 In addition, Vendor shall arrange to submit following documents along with
the consignment :

6.2.1 Detailed dimensioned, cross section drawing of each size of valve being offered
with parts/ material lists, weight etc. as manufacturers / API / Other relevant
applicable standard.

6.2.2 Drawings for valves with accessories like gear operator, extension bonnet,
extended stems with stands bypass etc. giving major salient dimensions.

6.2.3 Material test certificates (physical property, chemical composition & heat
treatment report, radiography etc.) of the pressure containing parts & for the other
parts shall also be furnished for verification during inspection.

6.2.4 Following supplementary documentation is required to be provided in line
with API-6D as given below:

a) NDE records;
b) Hardness test report on pressure-containing parts;
c) Heat treatment certification records (e. g. charts);
d) Pressure test / Leak test (Valve seat & Fugitive) & other test reports,
(Including pressure, test Duration, test medium and Acceptance
Criteria);
e) coating/plating certification;
f) Fire type-test certificates;
g) Material inspection certificates in accordance with ISO 10474 or EN
10204, as applicable (the purchaser shall specify the type of
Certification, and for which parts, when ordering);
h) Design verification by certification body/agency;


20
i) Installation, operation and maintenance instructions/manuals;

6.2.5 All the documents as listed above shall be submitted in 3 copies.

7 MARKING :

7.1 Valve markings, symbols, abbreviations etc. shall be in accordance with
Table 12 of API-6D. Vendors name, valve rating, material designation,
nominalsize, direction of flow (if any) etc.as specified in the table 12 of
API-6D shall be integral on the body.

7.2 Body/cover/closure stamping shall be performed using a low-stress die-stamp,
rounded V or Dot Face type. Each valve shall be provided with an austenitic
stainless steel nameplate securely affixed and so located that it is easily
accessible. The marking on the nameplate shall be visually legible.

7.3 Each valve shall be marked with API-6D Monogram

8 PAINTING / PREPARATION FOR SHIPMENT :

8.1 All non-corrosion-resistant valves shall be coated externally in accordance with
manufacturers standards, unless otherwise agreed.

8.2 Carbon steel valves shall be painted with two coats of inorganic zinc silicate
primer ( Min. 35 micron per coat) .
.
8.3 Flange faces, weld bevel ends and exposed stems shall not be coated.

8.4 Parts and equipment that have bare metallic surfaces shall be protected with a rust
preventative that can provide protection at temperatures up to 50 C (122 F).

8.5 After testing, all valves shall be drained and dried thoroughly. Valve shall be
suitably painted as above / vendors standard approved specifications.

8.6 Flanged, threaded and welding ends shall be blanked off to protect the gasket
surfaces, welding ends and valve internals during shipment. Machined surfaces
shall be protected against corrosion during shipment and storage.

8.7 Valves shall be protected from rust, corrosion and any mechanical
damage during Transportation, shipment and storage. The packages shall
be sea-worthy.

8.8 Rust preventive on machined surfacesshall be easily removablewith a
Petroleum solvent.


21

8.9 Each end of valves shall be protected with the following materials:

Flange Face : Wood, Wood fiber, Metal or Plastic cover
Beveled End : Wood, Wood fiber, Metal or Plastic cover
SW & SCRD End : Plastic Cap

The ends shall be securely attached to the valve ends by bolting, steel straps, Steel
clips or suitable friction-locking devices. The design of the covers shall Prevent the
valves from being installed unless the covers have been removed.

A warning label shall be attached to the protective cover with instructions to
remove, prior to installation, material from inside the valve that secures or supports
the disc.

Each valve shall be wrapped in a polythene / impervious sheet & packed separately
in wooden crate, properly secured to prevent damage during transportation.
Each box shall be clearly marked valve size, location of dispatch, Purchaser
companys name , UP marking & fragile warning.

The valve boxes shall be put in a large container for transportation as per
manufacturers standards separately for each Purchaser Company& location
of dispatch.

8.10 While, gate valve shall be shipped with the gate in the fully closed position.

8.11 Valves of size DN 200 (NPS 8) and larger shall be provided with lifting points,
unless otherwise agreed. The manufacturer shall verify suitability of the lifting
points.

9 SPARES& SPECIAL TOOLS :

9.1 Vendor shall submit list of standard spares of valves & actuators along
with unit rates with validity for 2 years.

9.2 Vendor shall submit list of specialtools, if required for maintenance of
valves along with unit rates with validity of 2 years.

10 WARRANTIES :


22

10.1 Deleted.

10.2 Vendor shall provide warranty for the performance of valves for 18 months from
date of dispatch or 12 months from date of installation, whichever is later subject
to not exceeding 24 months from date of dispatch.

10.3 Manufacturer shall have / develop adequate service support in India to provide
technical after sales service in India with in 48 hrs. Notice&shall guarantee supply
of parts, services for at least 10 years for all valves supplied by way of an
undertaking.

B) SPECIFICATION FOR ELECTRICAL MOTOR OPERATED VALVE
ACTUATORS


23

1.0 SCOPE :

The scope of this specification covers design, manufacture, assembly, shop testing and supply of
electrical motor operated valve actuators intended for fully / partially opening and closing
valve duty.

2.0 CODES AND STANDARDS :

2.1 The equipment shall comply with the requirements of latest revision of the following
standards issued by BIS (Bureau of Indian Standards) unless specified otherwise:

IS 9334 Electric Motor Operated Actuators
IS 13947 (Parts 1, 3, 4&5) Low Voltage Switchgear
IS4722 Rotating electrical machines Specification

IS-325 Three-phase Induction Motors

IS 2148 Flameproof enclosures for electrical apparatus

IS 4691 Degrees of protection provided by enclosure for rotating
electrical machinery

EN 50018

Electrical Apparatus for Potentially Explosive
Atmosphere [EEx(d)]

IEC 60079 Electrical apparatus to explosive gas atmosphere.

IEC 60529

Classification of degrees of protection provided by
Enclosures (IP codes).

IEC 60801

Electromagnetic compatibility of Industrial-Process
management and control equipment

IEC 61508

Functional Safety of Electrical/Electronic/
Programmable Electronic Safety Related Systems

IEC 61511

Functional safety Safety Instrumented Systems for
the Process Industry Sector

2.2 In case of imported equipment, the standards of the country of origin shall be applicable
if these standards are equivalent or more stringent that the applicable Indian standards.


24
2.3 The equipment shall also conform to the provisions of Indian Electricity Rules and other
statutory regulations currently in force in the country.

2.4 In case Indian standards are not available for any equipment, standards issued by IEC/
BS/ VDE/ IEEE/ NEMA or equivalent agency shall be applicable.

2.5 In case of any contradiction between various referred standards / data sheets and statutory
regulations, the following order of decreasing priority shall govern:

- Statutory regulations
- Data sheets&Job specifications
- Codes and standards
- Manufacturers standards

3.0 GENERAL REQUIREMENTS :

3.1 The offered equipment shall be brand new with state of the art technology and a proven
field track record. No prototype equipment shall be offered.

3.2 Vendor shall ensure availability of spare parts and maintenance support services for the
offered equipment for at least 15 years from the date of supply.

3.3 The vendor shall be responsible for design, engineering and manufacturing of the
complete actuator to fully meet the intent and requirements of this specification and
attached data sheets.

4.0 TECHNICAL SPECIFICATIONS

Each MOV actuator shall include the motor, actuator unit, gears, position indicators, limit
switches, hand wheel, electrical starter and controls, terminal box etc. as a self-contained
unit. The actuator shall be sized to provide adequate torque and/ or thrust to ensure the
complete intended travel of the valve under the worst operating and electrical power
supply conditions.

4.1 MOTOR:

4.1.1 The motor shall be 3-phase squirrel cage induction type unless specified otherwise in the
data sheet. It shall have totally enclosed non-ventilated construction.

4.1.2 The motor shall be designed for valve actuator service with high starting torque and shall
be suitable for Direct on line starting. It shall be rated for S2-15 minute duty and shall
conform to IS 325 or equivalent international standards.

4.1.3 The motor shall be provided with Thermostat (s) / thermister(s) embedded in the hot
spots of motor winding for protecting the motor.


25

4.1.4 The motor shall be suitable for operating the actuator at 75% of rated voltage at motor
terminals.

4.1.5 The motor shall have class F insulation with temperature rise limited to class B limits.
Motor winding shall be treated to resist corrosive agents and moisture.

4.1.6 Motor rotor shall preferably be of die-cast aluminum and, if brazed, shall be free from
phosphorous.

4.2 INTEGRAL STARTER AND CONTROL TRANSFORMER :

The reversing starter, control transformer and local controls shall be integral with the valve
actuator, unless specified otherwise in the date sheet. Solid state control of valve actuator
and electrically isolated interface for remote control requirement shall be provided,
wherever these features exist in manufacturers design.

The integral starter shall be supplied with the following devices:

a) Electrically and mechanically interlocked revering contactors for opening and
closing operations.
b) Control transformer with necessary tappings and protected with suitable easily
replaceable fuses.
c) Terminal block for external cable connection fully prewired for internal devices
of valve actuator.
d) MOV actuators operating with AC power supply shall be provided with
Instantaneous Phase reversal protection.

4.3 INTEGRAL PUSH BUTTON, SELECTOR AND CONTROL DEVICES :

The following local control devices shall be provided integral with the MOV actuator:

a) Push buttons for Opening/ Closing/ Stop or alternatively Open/ Close selector
switch shall be provided. OPEN & CLOSE push buttons should be of green & red
color respectively. Close operation shall be push type & Open operation shall be
press & rotate type

b) Local/ off/ Remote Selector switch shall be pad-lockable in each position.

c) Local continuous position indication from Valve fully open to Valve fully
closed position, which may be of analogue or digital type using mechanical
indication/ Indicating lamps /LEDs.

4.4 TORQUE AND TRAVEL LIMIT SWITCHES :


26

Torque limit switches shall be provided to protect the motor from over-loading by cutting-off the
power supply to motor during opening and closing operations. The limit switches shall be
preset. However, it shall be possible to set the value of maximum torque during closing
from 50% to 100% of rated torque of actuators. Travel limit switch shall be provided to
cut-off the power supply to the motor at the end of preset limit of valve travel. The
switches shall be provided with requisite number of potential-free contacts for valve
actuator operation and for indication on remote panels as specified in data sheet. Instead
of mechanical torque limit switches, magnetic pulse counter / encoders to measure and
control the smoke of actuator may be provided, wherever this feature exists in
manufacturers design.

4.5 CONTROL FACILITIES:
The internal controls and monitoring circuits shall be incorporated within the integral
starter along with transformer and control unit of valve actuator. Following remote
control and monitoring facilities are to be provided as a minimum:

_ MOV open command
_ MOV close command
_ MOV open status indication
_ MOV close status indication
_ Position status of Remote / Local / Off selector switch
-Continuous position indication at remote by installing potentio meter or current position
transmitter

Remote control facility shall be provided for all the actuators. The remote control circuits
shall be powered from internally derived control supply voltage. In order to cater to
remote control and indication requirements for Position of Remote /
Local / Off selector switch, an additional Monitoring relay/ auxiliary relays shall be
provided as a part of the valve actuator. As an alternative, a common status contact
indicating the availability of the MOV actuator for remote control may be
provided by monitoring the following:

- Loss of one or more phases of power supply
- Loss of control circuit supply
- Selector switch in local mode
- Local stop push button set to 'Off'
- Motor thermostat tripped
- Any other local fault / abnormal condition.

4.6 Hand Operation:

A hand wheel with hand auto lockable lever shall be provided for emergency operation
of the MOV. The energisation of the motor shall automatically re-engage power
operation.


27

4.7 Two wire control System :

MOV actuators shall be suitable for 2-wire control system. These actuators shall have
general purpose FCU card embedded for communicating with any make of master station
or the FCU shall also be compatible for direct communication on open type international
standard 2 wire serial communication protocols/ modbus for serial communication
directly. Individual field units connectable to a master station through asingle 2-core
cable loop for control and monitoring of the MOVsBidders shall provide open
communication protocol (eg. MODBUS RTU, FIELDBUS etc ;) for 2 wire connectivity.
Bidders are required to interface their 2-wire control systems with owner supplied PLCs
(provided with correspondingprotocol interface card) as applicable. Each field unit /
MOV actuator shall be addressable through a unique address code. All the diagnostics&
control features required as per these specifications shall be available through 2 wire
system. The actuators supplied for item no.2 shall be compatible with the master control
station of model pakscan II E of M/s Rotork. The actuators can be either K series or of
IQ series of M/s Rotork only.

4.8 REMOTE POSITION INDICATOR:

A 4-20 mA remote position transmitter shall be provided in the valve actuator . The remote
position indicator shall continuously indicate the position of travel of the valve.

4.9 NAMEPLATE:

Each motorized valve actuator shall be provided with a stainless steel nameplate furnishing the
following details, attached firmly to it at a place convenient for reading:

a) Actuator tag number as per data sheet
b) Motor kW rating, motor time rating, motor supply voltage, nominal motor phase
current, auxiliary switch rating
c) Maximum torque setting
d) Actuator enclosure type, lubricant type
e) Actuator type, wiring diagram number/ catalogue number, actuator serial number
A separate nameplate shall be provided for hazardous area application.

4.10 The enclosure of complete MOV actuator including motor, integral starter, control
transformer unit and all control devices shall have minimum IP-65 degree of ingress
protection.

4.11 WIRING AND TERMINALS:

All devices provided in the actuator shall be wired up to the terminal block. The contacts
for remote operation and indication shall also be wired up to the terminal block.
Minimum 10% spare terminals shall be provided for future interlocks. Internal wiring for


28
power and control circuits shall be appropriately sized for MOV actuator rating. Each
wire shall be identified at both ends using PVC ferrules. The terminal compartment shall
be separated from the inner electrical components of the actuator by means of a
watertight seal so that the actuator electrical components are protected from the ingress of
moisture and foreign materials when the terminal cover is removed during installation
and maintenance.

4.12 Vendor shall be solely responsible for the compatibility of the MOV actuator with the
valve and for the selection and sizing of various electrical devices and components in the
actuator.

4.13 The actuator shall be provided with minimum fouradequately sized cable entries viz.,
one for power cable and two for control cables. However, the actual number of control
cable entries in actuator with 2-wire control system shall be provided based on job
requirements as specified in data sheets/ specification for control systems for MOVs.
Suitable double compression cable glands shall be provided with each actuator for all
cable entries and sealing plugs for all control cable entries. The cable glands and plugs
shall be made of Nickel-plated brass.

5.0 REQUIREMENTS FOR HAZARDOUS AREAS:

Hazardous Area Classification and Protection : Instruments located in
hazardous area shall be certified to meet or exceed the electrical
hazardous area defined by Area classification.

The actuator accessories used shall be flame proof and suitable for hazardous area
ofZone 1, Group IIA/IIB, T3 or better for applications. Additionally all valve
associatedinstruments shall be weatherproof to IP65./PI67 Instruments certified for use in
thespecified hazardous area classification shall be recognized by authority like
FM,CENELEC, PTB, BASSEFA, ATEX , CCOE/PESO etc.

Actuators meant for hazardous areas shall meet the requirements of IS 2148, IEC 79 or
equivalent international standards . The manufacturer shall possess valid test certificates
issue by a recognized independent test house (CIMFR/ Baseefa/ LCIE/ UL/ FM or
equivalent) for the offered actuators. All indigenous equipment shall conform to Indian
standards and shall have been tested and certified by Indian testing agencies. All
equipment (indigenous and imported) shall also have valid statutory approvals as
applicable for the specified hazardous locations from Petroleum and Explosives Safety
Organization (PESO)/ CCE or any other applicable statutory authority. All indigenous
flameproof equipment shall have valid BIS license and corresponding marking as
required by statutory authorities.

5.2 Apart from the nameplate indicating the Tag NO. a separate nameplate shall also be
provided on each actuator to indicate the details of the testing agency (CIMER or


29
equivalent), test certificate number with date, statutory approval number with date,
approval agency (PESO/ CCE/ DGMS or equivalent), BIS license number with date,
applicable Gas group and Temperature class etc. the nameplate shall be riveted/ fixed
with screws and not pasted. In case any of the standard details listed above are embossed
on the enclosures, the same need not be repeated.

6.0 INSPECTION, TESTING AND ACCEPTANCE :

6.1 The equipment shall be subject to inspection by Owner or by an agency authorized by the
owner. Manufacturer shall furnish all necessary information concerning the supply to
Owner. During the course of manufacturing, the purchaser or his authorized
representative shall be free to visit the works and assess the progress of work and the
manufacturer shall render him all possible assistance to do so.

6.2 Following routine and acceptance tests shall be carried out at the manufacturers works
under his supervision and at his own cost for all the actuators in line with QAP approved
by the owners.

6.2.1 ROUTINE TEST : Functional and calibration test for torque and limit switches

6.2.2 ACCEPTANCE TESTS :

Response time test

Variation of supply voltage

Variation of frequency

Tests for motor (As per relevant IS/ IEC)

Life test

Test on output shaft

FOLLOWING TESTS SHALL BE PROVIDED PRIOR TO SHIPPING:

Actuator operation, Cycle (open-close) each valve with its actuator at least five times,
for proper actuator operation. Verify that valve position coincides with
positionindicators.
Opening -closing position
Actuator output speed & Open-Close time
Actuator travel setting


30
Operational torque test as per API 609. The maximum measured torque shall be
lessthan 75 % of the design torque specified by the valve manufacturer for
actuatorsizing.
FAT and SAT for the system

Two weeks notice shall be given to Owner for witnessing the final testing of the
complete assembly to ensure satisfactory operation of the MOV actuators. Type test
certificates shall be furnished with bids. Final acceptance of MOVs at site shall be subject
to successful testing of the MOV actuators with the valves.

6.3 Type test certificates, original drawings referred in certificates and statutory approval
certificates and BIS license, where applicable, shall be shown to the inspection agency on
demand. The certificates and BIS license must be valid at the time of dispatch.

6.4 Test certificates of bought-out components shall be shown to the inspection agency on
demand.

7 PACKING AND DISPATCH :

All the equipment shall be divided into multiple sections for protection and ease of handling during
transportation. The equipment shall be properly packed for the selected mode of
transportation, i.e. by ship, rail or trailer. The equipment shall be wrapped in polythene
sheets before being placed in crates/ cases to prevent damage to finish. The crates/ cases
shall have skid bottoms for handling. Special notations such as Fragile. This side up,
Center of gravity, Weight, Owners particulars, PO no. etc. shall be clearly and
indelibly marked on the packages together with other details as per purchases as per
purchase order.

The equipment may be stored outdoors for long periods before installation. The packing
shall be completely suitable for outdoor storage in areas with heavy rains and high ambient
temperature unless otherwise agreed. In order to prevent movement of equipment/
components within the crates, proper packing supports shall be provided. A set of
instruction manuals for erection, testing and commissioning, a set of operation and
maintenance manuals and a set of final drawings shall be enclosed in a waterproof cover
along with the shipment.

These precautions shall be read in conjunction with similar specifications for valves.

8 SPARES & SPECIAL TOOLS :

8.1 Vendor shall submit list of standard spares of Actuators along with unit
rates with validity for 2 years.

8.2 Vendor shall submit list of special tools, if required for maintenance of Actuators


31
along with unit rates with validity of 2 years.

9 WARRANTIES :

9.1 Vendor shall provide warranty for the performance of Actuators for 18 months from date of
dispatch or 12 months from date of installation, whichever is later subject to not
exceeding 24 months from date of dispatch.


32
JOB SPECIFICATION FOR INERNAL FIELD CONTROL UNIT (IFCU)
COMPATIBLE TO MASTER CONTROL STATION OF ROTORK CONTROLS MAKE
AND OF MODEL PAKSCAN II E

TECHNICAL SPECIFICATION FOR INTERNAL FIELD CONTROL UNIT (IFCU)

1. The IFCU shall comprise a single printed circuit board that shall directly connect to
the main PCB and shall fit inside the actuator electrical housing.
2. The IFCU processor shall be controlled by a programme stored in EPROM. The
ERROM shall be located on the unit board. Additionally the circuit shall include an
non-volatile EEPROM that shall be used to store parameters settings that contain
information about the field unit settings.
3. The 2-wire loop interface electronics shall also be on the field unit board. The
interface circuits shall be fully opto-isolated from the field unit processor and the
actuator electronics.
4. Operation and storage
a) The field unit is designed to be stored in the actuator and operated within the
same environment.
b) Operating/storage temperature: +1
0
C to +60
0
C.
c) Relative humidity : 5% to 95% (non condensing)
5. The field unit EPROM shall have to be compatible with the master station and to
loop protocol to which it is connected.
6. The field unit shall be field configurable by using a hand held terminal (HTT).
7. Each unit shall have a unique address and shall use the same loop protocol.
8. IFCU shall have provision for the connection of two-wire cable from previous
actuator and of two-wire cable to next actuator.
9. The field unit shall directly interface with the two wire loop. The interface shall
include protection devices to suppress the effects of lighting strikes or other high-
induced voltages.
10. IFCUs shall work on the current loop.
11. Loop back feature: The interface shall include circuits that permit the field unit to
loop back the current on the two wire loop if cable is broken.
12. Loop by pass circuit: If the actuator is powered off then the by-pass relay of the field
unit shall permit the loop current to flow through the actuator.
13. IFCU shall be able to provide the status of the following digital data bits:
a) Open position limit switch
b) Close position limit switch
c) Stop indication
d) Motor running indication
e) Motor running in open direction
f) Motor running in close direction
g) Loop back on
h) New alarm indication


33
i) Alarm indication
14. IFCU shall be able to provide the alarm status of the following data bits
a) Memory fault
b) Communication failure
c) Power on reset
d) Watch dog timer
e) Control not available
f) Local stop
g) Thermostat trip
h) Monitor relay
i) Start/stop failure
j) Obstructed valve, torque trip
k) Jammed valve, torque trip
l) Manual valve movement
m) Motor running at end of travel limit.
n)
Note: Any position alarm reveled by the field unit shall be reported to the master station.

15. Valve position feed back continuous position data shall be available.
16. The following command outputs shall be available
a) Open
b) Close
c) Stop
d) ESD
e) Full travel control which means when multiple commands are given to the same
field unit (IFCU), the command received last shall be executed.
17. Communication baud rate shall be in 5-steps and maximum of 2400 baud or better.
18. Field unit address shall be in the range from 1-240. The order of the addresses on the
loop not to be consecutive.
19. These IFCUs will be connected to master station which will support a loop length of
20km without any intermediate repeaters.


34
11.0 DATE SHEET FOR MOV ACTUATOR : PURCHASERS DATA

1.0 SITE CONDITIONS

S.NO.
1.1 Altitude Less than 1000 m Above MSL
1.2 Design ambient
temperature
-10 deg. To +55 deg. C
1.3 Humidity max. 100 %
1.4 MOV Tag Nos Will be intimated after award of contract.

2.0 SYSTEM CONDITIONS :

S.NO.
2.1 Supply Voltage 415V+ 10%, 3-phase AC for MOV
2.2 Supply Frequency 50 Hz + 3%
2.3 System Earthing Solidly Earthed

3.0 OPERATING ENVIRONMENT :

S.NO.
3.1 Area Classification : Zone 1
3.2 Gas Group : IIA/IIB
3.3 Temperature Class : T3
3.4 Construction : Flameproof Ex(d)
3.5 Ingress Protection : IP65
3.6 Painting : Epoxy base
3.7 Whether K-Mass type or
equivalent fire proofing required
: No
3.7.1 For MOV Tag Nos : Not Applicable.
3.7.2 With fireproof rating : Not Applicable
4.0 Valve Duty , Mode of Control and Devices for Control
4.1 Valve duty
a. Fully open and fully closed : Yes.
b. Partially open and partially closed : No
Control Requirement

: Local & Remote for all
MOVs
Local / Remote / Off selector switch on MOV
Actuator
: Required
Compatibility for interfacing with 2 wire
control system
: Required
Setting adjustable parameters of Actuator (
for 2 wire control system)
: From field for 2 wire
control


35

Continuous position indication

Local Mechanical / LCD
indication is required.
Remote Potentiometer / transducer for
remote continuous indication
Required in control room
thru Master Control
Station
Intermediate travel limit switch Required
Potentials free contacts for indication on
remote panel and other interlocks

For Valve Open Position Required
For Valve Closed Position Required
For remote indication or position of Local /
Remote selector switch
Required
For availability of MOV actuator Remote
Operation ( contact from monitoring relay)
Required
For indicating valve position in progress Not required
Remote emergency stop push button for
Stopping Actuator
Required.
DCS/PLC interface for Remote Control /
Indication
Remote Indication required
for all MOVs
time of operation
- Opening 1-Second per inch dia. of
the valve as the subject
application is of quick
opening/closing type.
- Closing 1-Second per inch dia. Of
the valve as the subject
application is quick
opening/closing type.
Make of MOV Actuator Rotork,Auma or
Limitorque. For item no.2
,it shall be of M/s Rotork
make only compatible
with Pack Scan II E.
Double Compression Glands & plugs ( for
unused entries ) , to be supplied with the
Actuator
Flame and weather Proof
Test and Approval Certificates for Flame Proof Actuators
For Indigenous make MOV
Actuators
Refer technical specifications of
Electrical MOV Actuators
For Imported make MOV
Actuators
Refer technical specifications of
Electrical MOV Actuators


36
Submission of Type Test
Certificates -
Yes
Notes :

1. N.A. denotes Not Applicable.

2. Area Classification Zone, Gas group and Temperature class indicated at 5 Nos. 3.1 to 3.3
above refer to IS/IFC standards.

3. Two separate earthing bosses shall be provided in each actuator. All the actuators shall be
controlled through 2 wire control station. The Master station , if available with the owner,
the new actuators shall be hooked to the existing Master station. Vendor to quote rates
including Internal Field Control Unit (IFCU) for actuators suitable for 2 wire control
system.Supply of master station is not in the scope of this tender.

4. The purchaser shall provide single point power supply to the actuator as per S.No.2
above. Any other control supply voltage required shall be internally derived by the
manufacturer within the actuator.

5. Vendor shall furnish complete data as per Part-II of this data sheet for each MOV
Actuator along with the offer.

6. Remote Input signals for opening / closing / stopping the MOV shall be
provided through the momentary closing of separate potential free contacts in owners
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.

DATA SHEET FOR MOV ACTUATOR


37
Part II: DATA BY VENDOR
(To be filled-in separately for each actuator and furnished along with the offer)

MOV Tag No.:

1.0 Actuator :
1.1 Make :
1.2 Type & Catalogue No. :
1.3 Applicable Wiring Diagram No. :
1.4 Valve duty
1.5 Maximum permissible number of :
Open/Close cycles per hour
1.6 Internal control supply used in actuator : V, AC/DC
1.7 Recommended backup HRC fuse rating :

2.0 Motor
2.1 Make :
2.2 KW rating :
2.3 Rated speed in RPM :
2.4 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 :

4.0 Test and approval certificates : Furnished/Not furnished

5.0 Component Makes

5.1 Contactors :
5.2 Push Buttons :
5.3 Selector Switches :

6.0 MOV Actuators suitable for wire control system

6.1 Maximum no. of field units that can be :
Connected to one master station
6.2 Maximum permissible distance from :
Field unit to the master station
6.3 Maximum number of Control inputs and : Control inputs
nos.
Control/ Status outputs from each field Control/Status outputs
nos.


38
Unit that can be handled through the
2 wire control system

12.0 Vendor data requirement MOV Actuator


39
S.No. Description With Bids Post order Final
Documents
For
Review
For
Ref./Rec
ords

1 Vendor Drawing/Document Submission
Schedule
* *
2 List of deviations, if any, to MR
requirements

3 Data Sheets (duly filled in * * *
4 G.A and mounting details of actuators * *
5 Wiring and Connection diagrams * *
6 QA Plan of Vendor * *
7 Shop Inspection Plan and Testing
Procedure
* *
8 Test Records *
9 Type Test Certificates for Flameproof /
Explosion proof equipment
* *
10 Recommended maintenance spares with
prices
*
11 Equipment storage procedure *
12 Data Books / Manuals
a. Installation Manual and
Standard
b. Operating/Maintenance Manual
c. Catalogues / Brochures
indicating complete technical
details and data for actuator
selection

*
*

*

*
13 Details of fireproofing, if specified in
data sheet
* * *

Notes :

1. Vendor shall furnish soft copy of all drawings and all documents inas part of final
documentation.

2. All technical details and documents furnished with bids shall be treated as data for
engineering. These shall however, be subject to Purchasers review after order placement
and bidder shall comply to MR/Tender requirements without any cost & time
implication.


40
QAP for DBB and Double isolation VALVES
SCOPE OF
INSPECTION
S.
No.
STAGE/
Activity
COMPONENT
CHARACTERISTICS
METHOD
OF
CHECK
QUANTUM
OF
CHECK
REFERENCE
DOCUMENTS
ACCEPTANCE
NORMS
RECORD SUB
VEN
DOR
V
E
N
D
O
R
TPI
1. Incoming raw
Materials /
components
Raw material
for fabrication
of valve body,
plate, flange etc
Surface Quality Visual As per Mfg Test
plan and
applicable code
As per Mfg Test
plan and
applicable code
As per Mfg Test
plan and
applicable code
Inspection
Report
W W R
2. do do Dimensions Measurement

As per Mfg Plan Approved
Drawing

Approved
Drawing
Inspection
Report
W W R
3. do do Chemical & Mech.
Prop.( Hardness,
bend, Tensile etc.)
Review of
Vendor
TC
All Heats As per relevant
Material
Spec

As per relevant
Material
Spec
Inspection
Report
Vendor
TC
W W R
4. WPS and
WPQ QAP
As per applicable
code
/specification
As per applicable
code
/specification

5.

Welding of
valve body,
bottom plate
& flanges
Valve body Weld joint fit-up Visual 10% of qty. as
per data sheet
(wherever
applicable)
As per applicable
code
/specification
As per applicable
code
/specification

W W R
6.

do do Radiography Visual 10% of qty. as
per data sheet
(wherever
applicable)
As per applicable
code
/specification
As per applicable
code
/specification

W W R
7. do do Ultrasonic
Examination
Visual 10% of qty. as
per data sheet
(wherever
applicable)
As per applicable
code
/specification
As per applicable
code
/specification
UT Scan
Report
W R R
8. Bought Out,
Finished&
Subcontract
items
Stems, Gaskets
Gear units,
Fasteners etc
Surface Defects Visual As per Mfg.
Sampling
Plan
App DWG /
Relevant Std.
App DWG /
Relevant Std.
Inspection
Report
W R R
9. Bought Out,
Finished &
Sub contract
Stems, Gaskets
Gear units,
Fasteners etc
Dimensions Measurement As per Mfg.
Sampling
Plan
App DWG /
Relevant Std.
App DWG /
Relevant Std.
Inspection
Report
W R R


41
items
10. do do Physical and
chemical properties
Review of TC
of supplier
As per Mfg.
Sampling
Plan
App DWG /
Relevant Std.
App DWG /
Relevant Std.
Inspection
Report
W R R
11. do thermal relief
valve
Hydro-test of Review of TC
of supplier
(100% )
As per Mfg.
Sampling
Plan
App DWG /
Relevant Std.
App DWG /
Relevant Std.
Inspection
Report
W R R
12. Product
Evaluation &
Testing
Finished
Valve

Hydrostatic shell test 100 % of the
valves of all
sizes & types
As per
applicable code
/specification
/app drawing
As per applicable
code
/specification
As per applicable
code
/specification
Test
Report
- W R
13. do do

Hydrostatic seat test 100 % of the
valves of all
sizes & types
do As per applicable
code
/specification
As per applicable
code
/specification
Test
Report
- W W
14. do do

Additional seat test 10 % of the
valves of all
sizes & types
code
/specification
As per applicable
code
/specification
Test
Report
- W W
15. do do

Anti-static testing 5 % of the
valves of each
size & type
code
/specification
As per applicable
code
/specification
Test
Report
- W R
16. do do

Torque/thrust
functional testing
1 % of the
valves of each
size & type
code
/specification
As per applicable
code
/specification
Test
Report
- W R
17. do do

Drive train strength
test
1 % of the
valves of each
size & type
do

As per applicable
code
/specification
As per applicable
code
/specification
Test
Report
- W R
18. do do

Fire Safe testing As per
applicable
specification
As per
applicable code
/specification
/app drawing

As per applicable
code
/specification
/app drawing
As per applicable
code
/specification
/app drawing
Test
Report
- W R
19. Product
Evaluation &
Testing
Finished
Valve

Functional/
Operational
Test (For Motor
/Actuator
Operated)
As per DWG. 100% App DWG App DWG Test Report ------ W H
20. Final
Inspection
Finished
Valve

Visual (TC
Verification, SL. No.
Marketing Flange
finish, Tag No.)
Visual &
Std. Measuring
Instruments
DP & MPI
Visual
100% and
dimensions at
random
App DWG App DWG Inspection
Report
------ W H


42
Bevel Dimensions &
Special Requirement
in PO
Of bevel
Surfaces
21. Packing Finished
Valve
------ At random ----- As per dispatch
instructions
App DWG &
Spec
---- ------- W R
22.
Strip Check,
Differential
hardness (see
notes)
Finished Valve Verify Components Visual 1 Valve per
Type/Size &
order
App DWG / PR App DWG &
Spec
Inspection
Report
--- N
A
NA

Legends: H-Hold (Offer for Witness & obtain clearance),W-Witness, R-Review, A-Approval, I-Information, X-Submit, PO-Purchase Order, PR-Purchase Requisition, Differential hardness
surveillance check & to be taken up before lapping is done normally, , DP-Dye Penetrate Test, UT-Ultrasonic examination,
All the NDT-Leak testing/Heat treatment/Special manufacturing procedures have to be specially approved or only previously approved procedures have to be used. In case of conflict between
purchase specification, purchase specification shall be applicable. This document describes generally the requirements pertaining to all types of valves. Requirements specific to the item are only
applicable.

Abbreviation:

WPS - Welding Procedure Specification
WPQ - Welders Performance Qualification
QAP - Quality assurance plan
Manufacturing Mgf
Specification Spec
App DWG - Approved Drawing
TC Test Certificate

Note: This QAP is to be further developed by Vendor in line with the tender specifications, applicable codes & standards and to submit for owners approval before manufacturing

Technical Specification

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DOUBLE BLOCK & BLEED AND DOUBLE ISOLATION VALVES

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