MATERIAL REQUISITION FOR VALVES

Transcription

1 Title: MATERIAL REQUISITION FOR VALVES Page: 1 of 19 MATERIAL REQUISITION FOR VALVES JUN-2013 ISSUED FOR APPROVAL M. KAMALOU A.MOHAMADIZADE A.MOHAMADIZADE REV. DATE STATUS PREPARED BY CHECKED BY APPROVED BY DOCUMENT REVISIONS

2 Title: MATERIAL REQUISITION FOR VALVES Page: 2 of 19 REVISION REVISION INDEX REVISION PAGE PAGE X 41 2 X 42 3 X 43 4 X 44 5 X 45 6 X 46 7 X 47 8 X 48 9 X X X X X X X X X X X APENDIXS

3 Title: MATERIAL REQUISITION FOR VALVES Page: 3 of 19 TABLE OF CONTENTS 1 SCOPE OF SUPPLY 4 2 GENERAL SUPPLY SPECIFICATION 5 3 TECHNICAL REQUIREMENTS OF SUPPLY 6 4 INSPECTION AND TESTING 12 5 INSPECTION AND TEST PLAN 16

4 PETROCHEMICAL RESEARCH & Title: MATERIAL REQUISITION FOR VALVES Page: 4 of 19 1 SCOPE OF SUPPLY 1.1 Bulk Material Supply Refer to MTO 900-BOM-A4-PD Document and Drawing Supply DESCRIPTION ISSUE DATE (1) FIRST ISSUE PURPOSE (2) QUANTITY TYPE (3) FINAL ISSUE (4) QUANTITY TYPE (3) Long storage instruction 2M before delivery IFR - 5+E Fabrication and quality control plan +6W IFR 2+E 3+E Inspection book (5) -0D IFR 1 3 Specification for packing and protection to materials during transit -5W IFR 4+E 5+E Packing list +4W IFR 3+E 5+E NOTES: (1) ISSUE DATE: + means Days (D) or Weeks(W) or Months(M) after Purchase Order effective date - means Days (D) or Weeks(W) or Months(M) before Delivery date (2) PURPOSE: IFR = Issue for review and comments / INFO = Issue for information (3) QUANTITY TYPE: Number of copies plus Electronic File (E) (4) FINAL ISSUE: Document without comments (5) INSPECTION BOOK: One additional copy shall be delivered together with the goods and indicated in the relevant Packing List.

5 Title: MATERIAL REQUISITION FOR VALVES Page: 5 of 19 2 GENERAL SUPPLY SPECIFICATION 2.1 Scope The requirements of this specification for the supply of valves supplement those required by the ITEM DESCRIPTION shown in the Material Requisition. 2.2 Reference Documents API ASTM ANSI MSS B.S.I. American Petroleum Institute American Society for Testing and Material American National Standard Institute Manufacturer Standardization Society British Standards Institution And all others codes, standards and specifications indicated in the ITEM DESCRIPTION, or in any reference document. Any conflict between the various requirements within the attached/referenced Codes, Standards and Specifications, shall be brought to NPCRT attention for clarification.

6 Title: MATERIAL REQUISITION FOR VALVES Page: 6 of 19 3 TECHNICAL REQUIREMENTS OF SUPPLY 3.1 Marking and Colour Code All valves shall be marked in accordance with MSS SP-25, and ANSI B In addition each valve shall be fitted with a rust-resistant metal tag stamped with the NPCRT code number, which shall be securely wired to the gland bolting or to the valve handwheel or other appropriate location, except the bolt holes of end flanges One strip of water-proof paint shall be provided for each valve according to the following table: - KILLED CARBON STEEL (LOW TEMP WHITE - CARBO-MOLY BLACK CR-0.5 MO ORANGE - 5 CR-0.5 MO RED - 9 CR-1 MO YELLOW - AISI 304 BLUE - AISI 304 L BLUE/WHITE - AISI 316 GREEN - AISI 316 L GREEN/WHITE - AISI 321/347 PINK - 3,5 Ni GREEN/YELLOW In case of dual marked the colour of straight grade shall be applied. Strip location shall be on the edge of flange ends, or on bonnet/body connection. 3.2 Packing, Protection during Transit and Long Storage Instructions Packing and protection during transportation to site shall be adequate to protect the Valves from any damage and corrosion during transit from point of manufacture to after

7 Title: MATERIAL REQUISITION FOR VALVES Page: 7 of 19 arrival at job site under conditions that may involve multiple handling, shocks and weathering, extended storage, exposure to moisture and sea atmosphere and to the possibility of pilferage. Goods must withstand 1 (one) year transit conditions without suffering damages. Vendor shall describe in his bid the type of packing and protection; type of packing and protection shall be specified in the Purchase Order (PO) Vendor shall supply Instructions for Long Storage (LSI) for a further 2 (two) years storage under site conditions. LSI shall cover the following topics: - description of packing and description of protections given for transit; - Storage facilities and procedures for conservative maintenance/procedures during storage The following are minimum requirements: A) The requirements of API 600/602 B) Austenitic stainless steel valves shall be protected from salt contaminated atmospheres, sea water spray or wetting, using water-proof barrier material. C) Heavy duty plastic or wooden disks as well as other suitable means shall be provided to protect flanged or butt-weld ends and to exclude foreign matter from the interior of the valve. In addition, flange gasket contact surfaces shall be protected with a removable rust preventive compound or strippable products, suitable for not less than 12 months outdoor storage. D) Plastic caps shall be provided on all threaded or socket ends.

8 Title: MATERIAL REQUISITION FOR VALVES Page: 8 of General Requirements All valves P/T rating Valves shall withstand fully pressure/temperature rating according to ANSI B16.5 / B For valves which do not fulfil this requirement due to the particular design (i.e. soft-seal, diaphragm, etc.), Vendor shall clearly specify P/T limitations Minimum body thickness for stainless steel and higher alloy valves shall be according to ANSI B Carbon steel and low alloy valves shall comply with API 600 thickness requirements Flanged cast valves up to 1½" may be supplied in forged material of equivalent type. Pressure-temperature rating line of cast material shall be guaranteed All flanged valves shall have integral type flanges. Valves with flanges welded to the body are not accepted, unless specified in the material requisition (when end flanges are required welded to the body, the welds shall conform with ANSI B31.3 ) Replaceable valve seats shall provide complete tightness without requiring sealing compound and/or gaskets Valve face-to-face as well as end-to-end dimension shall be ANSI B Deviation, if any, shall be submitted to NPCRT approval.

9 Title: MATERIAL REQUISITION FOR VALVES Page: 9 of Bolting material shall be according to the following, unless otherwise indicated in the valve description: - CS VALVES A193 B7/A194 2H - K.C.S. VALVES A320 L7/A194 A - 3,5 Ni VALVES A320 L7/A S.S. VALVES A320 B8/A194 8

10 Title: MATERIAL REQUISITION FOR VALVES Page: 10 of All valves supplied with pipe nipples welded on ends shall have welded zone post-weld heat-treated before assembly, unless otherwise stated on order. Heat treated procedures and welding techniques shall be as per ANSI B chapter V Nipples of valves supplied with nipples shall be ASTM A106 schedule Flange facing shall be as per ANSI B Visual roughness evaluation shall be according to ANSI B Austenitic stainless steel valves and/or valve parts shall be furnished in the solution annealed condition Gear operators shall be of enclosed design, seal tight box and protected stem. Unless otherwise specified by writing, they shall be "bevel gear type" (handwheel parallel to the valve stem) with handwheel to be capable to rotate by 90 degrees Lever operated valves shall be supplied with individual lever, wrench or handle Motorized valves shall have provisions to be operated manually Ball, plug and butterfly valves chain or gear operated, shall have an indicator to show open/closed position The valves (including gasket, bolting, packing and smaller internal parts) shall be suitable for the following min. temperature: - K.C.S. valves: -45 C - 3,5 Nickel valves: -100 C - S.S. valves: -150 C

11 Title: MATERIAL REQUISITION FOR VALVES Page: 11 of The Valves with asbestos free gasket or packing and aramidic fiber packing shall be suitable for potable water Forged valves in ASTM A105 material shall be supplied in the normalized condition (A105 N) Gate, globe, and check valves If butt-weld end valves are required with a hardness differential between seating surfaces, the wedge/plug seating surface shall be the "softer" material Valve of rating 300 lbs and larger shall be provided with a lantern ring Valves with renewable seats as alternative to integral seats are accepted Valves shall be fitted with undrilled bosses as per MSS-SP Unless otherwise agreed upon, Stellite shall be "weld deposited", N. 6 or equal composition type Valves specified complete with by-pass shall be as follows: - Valves up to 8 ; by-pass diameter 1/2 - Valves 10 up to 24 ; by-pass diameter The by pass gate valves shall be in accordance with API 600/ In any case the requirements of API 600 / ANSI B16.34 shall be followed.

12 Title: MATERIAL REQUISITION FOR VALVES Page: 12 of Ball valves Fire-safe valves shall be certified according to official standards All valves shall be designed to permit replacement of the ball, seats and seal Valves shall be provided with antistatic devices Valve design shall be according to ANSI B16.34 and BS When in contrast, the more stringent shall prevail Valves with weld ends shall be designed so that soft parts may be removed while welding. In any case the valve shall be guaranteed against the damage of the soft seal material due to heat during welding operation. Manufacturer recommendations on welding shall be included with the instruction manual Removal of handle shall be possible without disturbing the packing gland Valves having the ball extending past the flange face are unacceptable. 4 INSPECTION AND TESTING 4.1 General All valves prepared for NPCRT inspection shall have passed a preliminary inspection made by the Manufacturer's Quality Control. 4.2 Material Inspection All mill test certificates and manufacturer's test certificates, if any, shall be verified (for valve body and main components, such as wedge/disc, stem, seats, bolting, etc.). Chemical and mechanical characteristics, diagrams of any heat treatment, shall be according to those provided in the relevant Codes, Standards and/or Specifications.

13 Title: MATERIAL REQUISITION FOR VALVES Page: 13 of 19 The NPCRT inspector has the right to carry out any check test in order to verify the certified values in any case of doubt or dispute concerning the results obtained. Should be the results not according to the specifications, test costs shall be at Vendor's charge. 4.3 Visual Inspection Visual inspection shall be performed according to API 598. Non-destructive devices shall be used to check the performance of valve components (trim hardness, machining etc.). 4.4 Dimensional Inspection Main dimensions of the valves shall be verified fore compliance with the relevant codes, standards and/or specifications. (i.e. flanges bore diameter, face-to-face dimensions, etc.). 4.5 Non Destructive Examination (NDE) The extent of NDE (RX, MP, LP) shall be defined during the order phase but in any case the following shall be provided, as a minimum, when not specifically agreed: A) Welded pressure seams on welded constructed - 100% RX (where possible). B) Repair by welding. Repair procedure shall be submitted to NPCRT for approval. C) Hard facing by weld deposit. Liquid penetrant examination may be required by the inspector in order to verify the compactness of the layer. D) Valve ratings > 900. The following shall be provided: Ferritic alloy steel MP as per MSS SP 53 RX as per MSS SP-54 (1) Austenitic stainless steel LP as per ASTM E165/E125 (1) on critical areas as per ANSI B Tests shall be executed on 10% of castings from the seam heat/heat treatment (1 valve minimum) selected by the NPCRT inspector.

14 Title: MATERIAL REQUISITION FOR VALVES Page: 14 of 19 If a defective casting is found, all the remaining castings of the same heat shall be examined. E) Butt-weld end cast valves (all ratings): all bevels shall be 100% radiographically examined. 4.6 Valve Pressure Test A valve pressure test shall be carried out for all valves, according to API 598, unless otherwise requested. High pressure closure test is required for a minimum of 10% of valves of the same type and size/rating (minimum 1), unless otherwise stated for a specific project and specified in the inspection sheet (ITP). The acceptable leakage of metal sealed valves shall be according to API 598. In case of failure, other 3 valves per type, size/rating shall be tested. If another failure is verified, all valves shall be tested. No leakage is acceptable on soft-seal valves. Prior to pressure testing, all internal valve components shall be cleaned. External surfaces shall be unpainted and free of scale, weld spatter and other foreign matter. Only potable water (50 ppm chloride ion max.) shall be used for pressure testing of austenitic stainless steel valves. If chloride content is greater than 50 ppm up to 250 ppm, a sufficient quantity of sodium nitrate shall be added to provide a test medium of 0.5% by wt. sodium nitrate solution. The test water shall be drained after testing and valves dried. Stem packing using during the test shall be the same as finally supplied. No mechanical operation shall be carried out after test execution, unless to re-test the valves. Valves shall operated (open/closed) some time before to pass the required closure tests.

15 Title: MATERIAL REQUISITION FOR VALVES Page: 15 of Motor-Operated Valves In addition, the following shall be provided: A) Electric motor Check motor characteristics (supply voltage, electrical connection, number of phases, power, etc.). B) Final assembled valve (Electric/Pneumatic Actuator) C) Running test shall be provided to check: - travel - operating time - remote position indicator - torque limiters - manual control - limit switches - low pressure closure test. 4.8 Defects : Valves with defects in the shell of a Cast or Forged Carbon steel or Alloy valves, Revealed by inspection or test,shall be rejected,unless otherwise approved by NPCRT inspector,in such case shall be repaired as permitted by ANSI B16.34/ ASTM Relevant. 4.9 Inspection Book: Inspection Book for all types of valves, including Tests and material certificates, shall be submitted to NPCRT Inspector, during final inspection.

16 Title: MATERIAL REQUISITION FOR VALVES Page: 16 of 19 5 INSPECTION AND TEST PLAN This Inspection and test plan is an engineering document which defines for each type of equipment: The type and extent of Owner/Owner Representative involvement in each phase of fabrication, control and testing requiring an inspection The resulting Suppliers contractual obligations, in accordance with applicable Project General Purchase Conditions Note: The inspection and test plan of may under no circumstances be used as a substitute for the Suppliers Quality Control Plan 5.1 DEFINITION OF CONTRACTOR INVOLVEMENT The nature of involvement is indicated against each activity of fabrication and testing by means of the letters, H, W and R the meaning of which is the following: H: (Hold) Point The Supplier cannot carry out the specified controls and tests without Inspector attendance. Consequently, the attendance to witnessing is mandatory. The Supplier must notify OWNER by fax of the dedicated inspection activity at least fifteen (15) days in advance. W: (Witness) The Supplier must notify to OWNER of the dedicated inspection activity at least fifteen (15) days in advance. OWNER representative witnessing is not mandatory, but optional. When a percentage value is indicated (i.e. W 10%) the inspection activities will be witnessed on spot basis as per percentage indicated. If OWNER representative do not elect to be present, the Supplier may proceed with his own inspection, provided controls and tests records are made available to Inspector for review.

17 Title: MATERIAL REQUISITION FOR VALVES Page: 17 of 19 R: (Review) - Review of Documents The Supplier has either to submit to Inspector for comments the documents required prior to the performance of the dedicated activity or to transmit or make available for the review of Inspector the results of the controls and tests conducted, as the case may be. 5.2 SUPPLIER S FABRICATION AND QUALITY CONTROL PLAN The Supplier must issue a Fabrication and Quality Control Plan for each equipment. The Supplier s Fabrication and Quality Control Plan is a document which defines in a chronological manner the list of the operations of fabrication, controls and tests in accordance with his own know-how and with the requirements specified in Material Requisition. Following information shall be clearly specified against each operation: - Reference documents (drawings, procedures, etc.) - Acceptance criteria (code, etc.) - Recording documents for controls and tests - Involvement of the Quality Control department of the Supplier and/or his subsupplier This Supplier s Fabrication and Quality Control Plan will have to include all inspection activities defined in and Test Plan as well as all inspection activities scheduled by the Independent Inspection Authority and/or the Client For equipment of inspection levels 1, 2 and 3, the Supplier s Fabrication and Quality Control Plan will have to be submitted compulsory to OWNER for comments before the pre-inspection meeting is held.

18 Title: MATERIAL REQUISITION FOR VALVES Page: 18 of INSPECTION RELEASE CERTIFICATE This document issued by OWNER inspector, permits the Vendor to proceed with the packing and to notify the shipment

19 PETROCHEMICAL RESEARCH & Title: MATERIAL REQUISITION FOR VALVES Page: 19 of 19 INSPECTION LEVEL STAGE BEFOR FABRICATION Suborders check ACTIVITES DESCRIPTION Welders and N.D.E. operators qualifications R NPCRT REQ. OF CERTIF. Welding consumable certificates R YES APPLICABLE DOCUMENTS AND REMARKS For main materials and/or activities complete with all the technical attachments. R YES Where welded construction are employed Material test certificates R YES Type EN B N.D.E. on raw materials R YES If required DURING FABRICATION Final N.D.E. R YES If any Post weld heat treatment R YES Recorded chart (If any) Hardness test of welds R YES If any Impact test R YES If any FINAL TEST Visual Check W Dimensional check W Pressure test W YES Leakage test W YES Low and High pressure closure test/back seat test W YES If any Positive Material Identification (P.M.I) R YES If applicable Exposed machined surface protection check W Marking check W Painting check R YES Fire Safe statement R YES If required DOC. Final inspection book H