NFPS Offshore Compression Complexes Project COMP2

COMPANY Contract No.: LTC/C/NFP/5128/20 CONTRACTOR Project No.: 033734

Document Title

:

SPECIFICATION FOR MANUAL VALVES FOR CP6S AND CP7S COMPLEXES

COMPANY Document No.

: 200-20-PI-SPC-00016

Saipem Document No.

: 033734-A-D-00-SPM-TB-S-10007

Discipline

: PIPING

Document Type

: SPECIFICATION

Document Category/Class

: 1

Document Classification

: Internal

B

A

12-Jul-2023

Issued for Approval

Khairul Harun

Safrul Heizaq

Suhaili/Matteo

21-Feb-2023

Issued for Review

Khairul Harun

Safrul Heizaq

Suhaili/Matteo

REV.

DATE

DESCRIPTION OF REVISION

PREPARED BY

CHECKED BY

APPROVED BY

Saipem S.p.A.

THIS DOCUMENT IS PROPERTY OF QATARGAS. THIS DRAWING OR MATERIAL DESCRIBED THEREON MAY NOT BE COPIED OR DISCLOSED IN ANY FORM OR MEDIUM TO THIRD PARTIES, OR USED FOR OTHER THAN THE PURPOSE FOR WHICH IT

HAS BEEN PROVIDED, IN WHOLE OR IN PART IN ANY MANNER EXCEPT AS EXPRESSLY PERMITTED BY QATARGAS.

Company No._Rev. 200-20-PI-SPC-00016_B

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2023.07.12 18:14:06 +08’00’Khai HarunDigitally signed by Aliaa AliminDN: cn=Aliaa Alimin, ou=Users, email=Aliaa.Alimin@Worley.comDate: 2023.07.12 18:20:49 +08’00’Aliaa AliminDigitally signed by Suhaili YunusDN: cn=Suhaili Yunus, ou=Users, email=Suhaili.Yunus@Worley.comDate: 2023.07.12 18:37:48 +08’00’Suhaili YunusMAGNANI MATTEODigitally signed by MAGNANI MATTEO DN: cn=MAGNANI MATTEO, o=SAIPEM, ou=LAPI, email=matteo.magnani@saipem.com, c=US Date: 2023.07.12 18:56:28 +08’00’

NFPS Offshore Compression Complexes Project COMP2 SPECIFICATION FOR MANUAL VALVES FOR CP6S AND CP7S COMPLEXES

REVISION HISTORY

Revision

Date of Revision

Revision Description

A1

A

B

13-Feb-2023

21-Feb-2023

12-Jul-2023

Issued for Inter-Discipline Check

Issued for Review

Issued for Approval

HOLDS LIST

Hold No

Hold Description

Company No._Rev. 200-20-PI-SPC-00016_B

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NFPS Offshore Compression Complexes Project COMP2 SPECIFICATION FOR MANUAL VALVES FOR CP6S AND CP7S COMPLEXES

TABLE OF CONTENTS

1

INTRODUCTION … 5

1.1

1.2

Project Objective … 5

Project Scope … 5

2

DEFINITIONS AND ABBREVIATIONS … 7

2.1

2.2

Definitions … 7

Abbreviations … 8

3

REGULATION, CODES AND STANDARDS … 10

3.1

3.2

3.3

3.4

Company Documents … 10

Project Documents … 11

Contractor Documents … 11

International Codes and Standards … 12

4

5

Purpose of document … 16

VALVE MATERIAL REQUIREMENTS … 16

5.1

5.2

5.3

5.4

5.5

5.6

5.7

5.8

General … 16

Non-Metallic Materials in Sour Service … 19

Elastomers… 20

Thermoplastics … 20

Non-Metallic Sour Service Limitations … 20

Seat Seals … 21

Stem Seals and Packing … 22

Gaskets … 23

6

DESIGN AND ENGINEERING REQUIREMENTS … 24

6.1

6.2

General … 24

Cavity Relief … 25

6.3 Wafer And Wafer Lug Valves … 25

6.4

6.5

6.6

6.7

6.8

6.9

Gate Valves … 26

Ball Valves … 26

Check Valves… 29

Globe Valves … 30

Butterfly Valves … 30

Double Block and Bleed Valves… 32

6.10

Valve Operators - Lever and Hand Wheel … 32

6.11

Valve Operators – Gear … 34

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NFPS Offshore Compression Complexes Project COMP2 SPECIFICATION FOR MANUAL VALVES FOR CP6S AND CP7S COMPLEXES

7

INSPECTION AND TESTING … 35

7.1

7.2

7.3

7.4

7.5

7.6

7.7

General … 35

Visual Examination … 36

Pressure Tests … 36

Test Medium … 39

Supplementary Test Requirements… 39

Inspection Levels … 40

Extent of Inspection and Witnessing … 41

8

PREPARATION FOR SHIPMENT … 42

8.1

8.2

8.3

8.4

8.5

General … 42

Protective Coatings … 42

Valve Protection … 42

Identification and Labelling … 42

Documentation … 43

9

Appendices … 44

Appendix 1

Seal Qualification … 44

Appendix 2

Reason for Elastomer Seal Qualification … 49

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NFPS Offshore Compression Complexes Project COMP2 SPECIFICATION FOR MANUAL VALVES FOR CP6S AND CP7S COMPLEXES

1

INTRODUCTION

The North Field is the world’s largest natural gas field and accounts for nearly all of the state of Qatar’s gas production. The reservoir pressure in the North Field has been declining due to continuous production since the early 1990s. The principal objective of the NFPS Project is to sustain the plateau from existing QG South Operation (RL Dry Gas, RGE Wet gas) and existing QG North Operation (QG1 & QG2) production areas by implementing an integrated and optimum investment program consisting of subsurface development, pressure drop reduction steps and compression. Refer to the figure below for a schematic of the North Field.

Qatargas Operating Company Limited is leading the development of the North Field Production Sustainability (NFPS) Project.

1.1 Project Objective

The objective of this Project includes:

• Sustain the Qatargas North Field Production Plateau by installing new Compression Complex facilities CP6S & CP7S in QG south with integration to the existing facilities under Investment #3 program.

• Facility development shall be safe, high quality, reliable, maintainable, accessible, operable,

and efficient throughout their required life.

• Achieve standards of global excellence in Safety, Health, Environment, Security and Quality

performance.

1.2 Project Scope

The Project Scope includes detailed engineering, procurement, construction, transportation & installation, hook-up and commissioning, tie-in to EXISTING PROPERTY and provide support for start- up activities of the following facilities and provisions for future development. The WORK shall be following the specified regulations, codes, specifications and standards, achieves the specified performance, and is safe and fit‐for‐purpose in all respects.

Offshore

CP6S and CP7S Compression Complexes that are part of QG-S RGE facilities as follows:

• CP6S Compression Complex

• Compression Platform CP6S, Living Quarters LQ6S, Flare FL6S

• Bridges BR6S-2, BR6S-3, BR6S-4, BR6S-5

• Bridge linked Tie-in to RP6S

Production from existing wellheads (WHP6S & WHP10S) and new wellhead (WHP14S) are routed via riser platform RP6S to compression platform CP6S to boost pressure and export to onshore via two export lines through the existing WHP6S pipeline and a new 38” carbon steel looping trunkline from RP6S (installed by EPCOL). CP6S is bridge-linked to RP6S.

• CP7S Compression Complex

• Compression Platform CP7S, Living Quarters LQ7S, Flare FL7S

• Bridges BR7S-2, BR7S-3, BR7S-4, BR7S-5

• Bridge linked Tie-in to RP7S

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NFPS Offshore Compression Complexes Project COMP2 SPECIFICATION FOR MANUAL VALVES FOR CP6S AND CP7S COMPLEXES

CP7S shall receive production from existing wellheads (WHP5S & WHP7S) and new wellhead (WHP13S). There is only one export line for CP7S through the existing export pipeline from WHP7S. CP7S is bridge-linked to RP7S.

RGA Complex Destressing

Migration of the Electrical power source, Telecoms, Instrumentation and Control systems from WHPs and RPs hosted by RGA to the respective Compression Complexes listed below:

• WHP6S, WHP10S, WHP14S, RP6S and RP10S to CP6S Compression Complex

• WHP5S, WHP7S, WHP13S and RP7S to CP7S Compression Complex

Destressing of Telecoms, Instrumentation and Control system in RGA Complex Control Room, which would include decommissioning and removal of telecom system devices and equipment that would no longer be required post migration and destressing activity.

Onshore

An Onshore Collaborative Center (OCC) will be built under EPC-9, which will enable onshore based engineering teams to conduct full engineering surveillance of all the offshore facilities. The OCC Building will be located in Ras Laffan Industrial City (RLIC) within the Qatar Gas South Plot. MICC & Telecommunication, ELICS related scope will be performed in the OCC building.

Figure 1.2.1: NFPS Compression Project COMP2 Scope

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NFPS Offshore Compression Complexes Project COMP2 SPECIFICATION FOR MANUAL VALVES FOR CP6S AND CP7S COMPLEXES

2 DEFINITIONS AND ABBREVIATIONS

2.1 Definitions

Definition

Description

COMPANY

Qatargas Operating Company Limited.

CONTRACTOR

Saipem S.p.A.

DELIVERABLES

FACILITIES

MAY

All products (drawings, equipment, services) which must be submitted by CONTRACTOR to COMPANY at times specified in the contract. All machinery, apparatus, materials, articles, components, systems and items of all kinds to be designed, engineered, procured, manufactured, constructed, supplied, tested and permanently installed by CONTRACTOR at SITE in connection with the NFPS Project as further described in Exhibit 6.

fabricated,

The word “may” is to be understood as an action to be undertaken at CONTRACTOR/COMPANY’s direction and upon evaluation of a review of the Circumstances of the issue in the question.

MILESTONE

A reference event splitting a PROJECT activity for progress measurement purpose.

PROJECT

NFPS Offshore Compression Complexes Project COMP2

SHALL

The word “Shall” is to be understood as a mandatory requirement.

SHOULD

The word “Should” is to be understood as a strongly recommended.

SITE

(i) any area where Engineering, Procurement, Fabrication of the FACILITIES related to the CP6S and CP7S Compression Complexes are being carried out and (ii) the area offshore required for installation of the FACILITIES in the State of Qatar.

SUBCONTRACT

Contract signed by SUBCONTRACTOR and CONTRACTOR for the performance of a certain portion of the WORK within the Project.

SUBCONTRACTOR

Any organization selected and awarded by CONTRACTOR to supply a certain Project materials or equipment or whom a part of the WORK has been Subcontracted.

WORK

Scope of Work defined in the CONTRACT.

WORK PACKAGE

The lowest manageable and convenient level in each WBS subdivision.

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Definition

Description

VENDOR

The person, group, or organization responsible for the design, manufacture, testing, and load-out/shipping of the Equipment/ Material.

2.2 Abbreviations

Code

Definition

AED

API

ASME

ASTM

BS

CRA

CSCC

DGE

DN

DOC

ED

ENP

EPC

EPDM

FEED

FRP

H2S

HNBR

IDBB

ISO

Anti-Explosion Decompression

American Petroleum Institute

American Society of Mechanical Engineers

American Society for Testing and Materials

British Standards

Corrosion-Resistant Alloy

Chloride Stress Corrosion Cracking

Dry Gas Export

Diameter Nominal

Doha Operating Center

Explosive Decompression

Electroless Nickel Plating

Engineering Procurement and Construction

Ethylene Propylene Diene Monomer

Front End Engineering Design

Fiberglass- Reinforced Plastic

Hydrogen Sulfide

Hydrogenated Nitrile Butadiene Rubber

Isolation Double Block & Bleed

International Organization for Standardization

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NFPS Offshore Compression Complexes Project COMP2 SPECIFICATION FOR MANUAL VALVES FOR CP6S AND CP7S COMPLEXES

Code

Definition

Low-Temperature Carbon steel

Material Test Reports

National Association of Corrosion Engineering

Non-destructive Examination

National Fire Protection Association

North Field Production Sustainability

Nominal Pipe Size

National Pipe Thread per ASME B1.20.1

Outside Diameter

Polyether Ether Ketone

Process and Instrumentation Diagram

Positive Material Identification

Parts per million

Procedure Qualification Records

Polytetrafluoroethylene (E.g., Dupont Teflon) (also abbreviated as TFE)

Qatargas Company Limited

Rapid Gas Decompression

Reinforced Polytetrafluoroethylene

Slim Double Block & Bleed

Stainless steel

Welding Procedure Specifications

LTCS

MTR

NACE

NDE

NFPA

NFPS

NPS

NPT

OD

PEEK

P&ID

PMI

ppm

PQR

PTFE

QG

RGD

RPTFE

SDBB

SS

WPS

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3 REGULATION, CODES AND STANDARDS

In general, all design activities shall confirm to legal and statutory regulations and recognized industry best practices. Conflict among applicable specification and / or codes shall be brought to the attention of the COMPANY for resolution COMPANY decision shall be final and shall be implemented. The latest editions of codes and specification effective as on date of contract shall be followed.

In general, the order of precedence shall be followed:

a) Qatari Governmental and Regulatory Requirements

b) COMPANY Procedures, Policies and Standards (Exhibit 5 Appendix I)

c) Project Specifications.

d) Industry Codes and Standards

e) COMPANY and CONTRACTOR’s Lessons Learned

If CONTRACTOR/SUBCONTRACTOR deems any deviations from the specifications will result in significant project cost and schedule saving, proposal to such deviations shall be submitted to COMPANY for review and approval. CONTRACTOR/SUBCONTRACTOR shall not proceed with any deviation to the specifications without prior COMPANY approval. In general, all design activities shall conform to legal and statutory regulations, and recognized industry best practices.

The following is a list of relevant regulations, codes, standards, specification, Company documents that shall be considered for the Project in the order of precedence listed above.

3.1 Company Documents

S. No

Document Number

Title

PRJ-PJL-PRC-080_02

AIMS: Tag Management System (TMS)

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3.2 Project Documents

S. No

Document Number

Title

200-20-PI-SPC-00015

200-20-PI-SPC-00017

200-20-PI-SPC-00018

200-20-CE-SPC-00018

200-20-CE-SPC-00020

200-20-CE-SPC-00015

200-20-PI-DTS-00026

200-20-PI-DTS-00025

200-20-PI-DTS-00024

200-20-PI-DTS-00022

200-20-PI-DTS-00021

200-20-PI-DTS-00023

200-20-CE-SPC-00014

200-20-CE-DEC-00003

200-20-PR-DEC-00022

200-20-SH-SPC-00011

200-20-CE-SPC-00019

Piping Material Specification Design for CP6S and CP7S Complexes Specification For Flanges and Hubs for CP6S and CP7S Complexes Specification For Bolts, Nuts, And Gaskets for CP6S and CP7S Complexes CRA Weld Overlay for Piping Materials Specification for CP6S and CP7S Complexes Specification For Positive Material Identification (PMI) for CP6S and CP7S Complexes Painting Specification for CP6S and CP7S Complexes

Datasheets for Manual Ball valves for CP6S and CP7 Complexes Datasheets for Gate, Globe and Check valves (2” and above) for CP6S and CP7 Complexes Datasheets for Gate, Globe and Check valves (Up to 1 ½) for CP6S and CP7 Complexes Datasheets for Double Block and Bleed Valves for CP6S and CP7 Complexes Datasheets for Butterfly valves for CP6S and CP7 Complexes Datasheets for Dual Plate Check valves for CP6S and CP7 Complexes Material Corrosion Requirements Sour Service System for CP6S and CP7S Complexes. Material Selection Philosophy Complexes Isolation Philosophy for CP6S and CP7S Complexes

for CP6S and CP7S

HFE Workplace Design Specification for CP6S and CP7S Complexes Welding and Non-Destructive Examination Specification for CP6S and CP7S Complexes

(NDE)

3.3 Contractor Documents

S. No

Document Number

Title

Not Applicable.

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3.4

International Codes and Standards

3.4.1 API – American Petroleum Institute

S. No

Document Number

Title

API SPEC 6A

Specification for Wellhead and Tree Equipment (2018)

API SPEC 6D

Specification for Valves (2021)

API SPEC 6FA

Specification for Fire Test for Valves (1999)

API STD 594

API STD 598

API STD 600

API STD 602

API STD 607

API STD 608

API STD 609

API STD 622

API STD 623

Check Valves: Flanged, Lug, Wafer and Butt-welding (2022) Valve Inspection and Testing (2016)

Steel Gate Valves - Flanged and Butt-Welding Ends, Bolted Bonnets (2021)

Gate, Globe, and Check Valves for Sizes DN100 (NPS 4) and Smaller for the Petroleum and Natural Gas Industries (2022)

Fire Test for Quarter-turn Valves and Valves Equipped with Nonmetallic Seats (2022)

Metal Ball Valves - Flanged, Threaded, and Welding Ends (2020)

Butterfly Valves: Double Flanged, Lug- and Wafer-Type and Butt-welding Ends (2021)

Type Testing of Process Valve Packing for Fugitive Emissions (2018)

Steel Globe Valves - Flanged and Butt-welding Ends, Bolted Bonnets (2021)

3.4.2 ASME–American Society of Mechanical Engineers

S. No

Document No.

Document Title

ASME B16.5

Pipe Flanges and Flanged Fittings NPS 1/2 Through NPS 24 Metric/Inch Standard (2020)

ASME B16.10

Face to Face and End to End Dimensions of Valves (2022)

ASME B16.25

Buttwelding Ends (2017)

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S. No

DOCUMENT NO.

DOCUMENT TITLE

4. ASME B16.34

Valves - Flanged, Threaded, and Welding End (2020)

5. ASME B16.47

Large Diameter Steel Flanges NPS 26 Through NPS 60 Metric/Inch Standard (2020)

6. ASME B31.3

Process Piping (2022)

3.4.3 EEMUA – Engineering Equipment and Materials Users Association

S. No

DOCUMENT NO.

DOCUMENT TITLE

1. EEMUA 192

Guide for the Procurement of Valves for Low Temperature (non- cryogenic) Service (1998)

3.4.4 ASTM – American Society for Testing and Material

S. No

Document No.

Document Title

1. ASTM A105/A105M

Standard Specification for Carbon Steel Forgings for Piping Applications (2021)

2. ASTM A182/A182M

3. ASTM A216/A216M

4. ASTM A350/A350M

Standard Specification for Forged or Rolled Alloy and Stainless-Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service (2022)

Standard Specification Suitable Service (2021)

for Fusion Welding,

for Steel Castings, Carbon, for High-Temperature

Standard Specification for Carbon and Low-Alloy Steel Forgings, Requiring Notch Toughness Testing for Piping Components (2018)

5. ASTM A351/A351M

Standard Specification Pressure-Containing Parts (2018)

for Castings, Austenitic,

for

6. ASTM A352/A352M

Standard Specification for Steel Castings, Ferritic and Martensitic, for Pressure-Containing Parts, Suitable for Low-Temperature Service (2021)

7. ASTM A487/A487M

Standard Specification for Steel Castings Suitable for Pressure Service (2021)

8. ASTM A494/A494M

Standard Specification for Castings, Nickel and Nickel Alloy (2022)

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S. No

Document No.

Document Title

9. ASTM A694/A694M

Standard Specification for Carbon and Alloy Steel Forgings for Pipe Flanges, Fittings, Valves, and Parts for High-Pressure Transmission Service (2016)

10. ASTM A703/703M

Steel Castings, General Requirements, for Pressure- Containing Parts (2020)

11. ASTM A961/961M

12. ASTM A995/995M

13. ASTM B148

14. ASTM B367

15. ASTM B381

Standard Specification for Common Requirements for Steel Flanges, Forged Fittings, Valves, and Parts for Piping Applications (2021)

Standard Specification for Castings, Austenitic-Ferritic (Duplex) Stainless Steel, for Pressure-Containing Parts (2020)

Standard Specification Castings (2018)

for Aluminium-Bronze Sand

Standard Specification for Titanium and Titanium Alloy Castings (2022)

Standard Specification for Titanium and Titanium Alloy Forgings (2021)

16. ASTM B564

Standard Specification for Nickel Alloy Forgings (2022)

17. ASTM B733

18. ASTM E446

Standard Specification for Autocatalytic (Electroless) Nickel-Phosphorus Coatings on Metal (2022)

Standard Reference Radiographs for Steel Castings Up to 2 in. (50.8 mm) in Thickness (2020)

3.4.5 BSI–British Standards Institution

S. No

Document No.

Document Title

1. BSI BS EN ISO 15761

2. BSI BS EN ISO 15848-1

Steel Gate, Globe and Check Valves for Sizes DN 100 and Smaller, for the Petroleum and Natural Gas Industries (2020)

Industrial Valves - Measurement, Test and Qualification Procedures for Fugitive Emissions - Part 1: Classification System and Qualification Procedures for Type Testing of Valves (2015)

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S. No

Document No.

Document Title

3. BSI BS EN ISO 15848-2

4. BSI BS EN ISO 23936-1

5. BSI BS EN ISO 23936-2

6. BSI BS ISO 28921

Industrial Valves - Measurement, Test and Qualification Procedures for Fugitive Emissions - Part 2: Production Acceptance Test of Valves (2015)

Oil and Gas Industries Including Lower Carbon Energy — Non-metallic Materials in Contact with Media related to oil and gas production — Part 1: Thermoplastics (2022)

Petroleum, Petrochemical and Natural Gas Industries — Non-metallic Materials in Contact with Media related to oil and gas production — Part 2: Elastomers (2012)

Industrial Valves - Isolating Valves for Low-Temperature Application Part 1: Design, Manufacturing and Production Testing (2022)

3.4.6 ISO – International Organization for Standardization.

S. No

Document No.

Document Title

ISO 10497

Testing of Valves - Fire Type-Testing Requirements (2022)

ISO 15156/ NACE MR0175

Petroleum and Natural Gas Industries Materials for Use in Oil and Gas in H2S-Containing Environments Production (2020)

3.4.7 MSS SP – Manufacturers Standardization Society

S. No

DOCUMENT NO.

DOCUMENT TITLE

1. MSS SP 55

Quality Standard for Steel Castings for Valves, Flanges, Fittings, and Other Piping Components. - Visual Method for Evaluation of Surface Irregularities (2011)

2. MSS SP 80

Bronze Gate, Globe, Angle and Check valves (2019)

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4 PURPOSE OF DOCUMENT

The purpose of this document is to define the minimum requirements for the Valve components used in design, fabrication, construction and testing of all process and utilities for the Topside piping. This document shall be read in conjunction with the applicable valve datasheets.

5 VALVE MATERIAL REQUIREMENTS

5.1 General

5.1.1 For Isolation type (Type A, B, C) refer to Isolation Philosophy for CP6S and CP7S Complexes (200-20-PR-DEC-00022) and all isolation valves shall be suitable for bi-directional flow.

5.1.2 Materials for valves and components shall be as specified in the respective valve datasheets

and shall meet project specification requirement and material selection basis.

5.1.3 All body and trim components of a valve shall be suitable for the full range of temperature, full range of pressure / full vacuum as per respective data sheets and piping class i.e., suitable for the pressure / temp corresponds to the design pressure and fluid services. This shall apply to all non-metallic (soft) materials such as seat /stem sealing materials, used within the valve.

5.1.4 All Valves shall be suitable for Standard ASME Design Pressure Rating corresponding to Valve

Pressure Class.

5.1.5 Materials for valves specified for sour service shall meet the requirements of NACE MR0175/ISO

15156 Region 3.

5.1.6 Precipitation hardened martensitic steel 17-4PH stainless steel materials shall not be used in sour service as per Material Corrosion Requirements Sour Service System for CP6S and CP7S Complexes (200-20-CE-SPC-00014).

5.1.7 Nickel alloy materials (UNS N06625) shall be annealed materials only, with the chemical composition, mechanical properties, heat treating requirements, and grain size requirements complying with ASTM A 494/ASTM B 564 as applicable.

5.1.8 CRA valve body and trim, including CRA cladded valves, if used, shall be verified using Positive Material Identification (PMI) according to the specification 200-20-CE-SPC-00020 “Specification for Positive Material Identification (PMI) for CP6S and CP7S Complexes.

5.1.9 Carbon steel valve bodies used for corrosive services shall be cladded with Nickel Alloy materials (UNS N06625) fitted with seats that require non-metallic O-rings/seals to prevent bypassing between the seat and the body (e.g., trunnion type ball valves, etc.) shall have the body seat pockets overlaid with a (UNS N06625) Nickel Alloy material. Additionally, the stem sealing area of the body shall be overlaid with the same CRA material.

5.1.10 Trim selection for gates, globes, and checks shall be as per API STD 600 Edition 2021 Annexure D “Valve Material Combinations” and API STD 602 Edition 2022 Annexure G “Valve Material Combinations” also individual valve datasheets, except as follows:

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Valve trim for low temperature carbon steel (LTCS) valves shall be API trim 12 or superior material as per valve datasheets.

CRA valve body which trim is not specified shall have a corrosion resistance equal to or exceeding the corrosion resistance of the CRA valve body/overlay material.

5.1.11 Threaded-end valves made of cast iron, malleable iron, or ductile iron are not permitted.

5.1.12 Only for SS Material piping classes, small bore valve bodies shall be made of either 316 or 316L stainless steel for non-welded end connections and of 316L stainless steel for welded end connections. In no case shall such valves installed in offshore locations be permitted to operate at temperatures higher than 65 °C (150 °F).

5.1.13 Small diameter (typically < NPS 2) bolted body (e.g., three-piece body design) valves employing

stainless steel bolts are not permitted in any offshore environment (i.e., marine).

5.1.14 Deleted.

5.1.15 Cast Valve body is proposed for Valves NPS 2” and above. Forgings is acceptable in place of

casting. The NDE requirement shall be as per ASME B16.34.

5.1.16 Cast alloy valves made from ASTM A494 Grade N7M shall not be used.

5.1.17 Stock bar material is not acceptable for valve body and its internal. Forged body shall be used for valves of 2” diameter and below and when the starting bar diameters is no greater than 8”. Material certification as per Type 3.2 for Sour Service application needed.

5.1.18 API trim numbers referenced in the valve descriptions and or piping component specifications shall meet the requirements of API STD 600 unless another API standard is applicable. Trim substitutions permitted by the API standards are acceptable.

5.1.19 Valve body and associated pressure-retaining components shall be Charpy impact tested in accordance with applicable ASTM material standards. Charpy test it is required for all Carbon Steel with Minimum Impact Test value: Min. 24 J average impact value of a set of three specimens ISO-V with Minimum 19 J for individual specimen at -29°C.

5.1.20 Yoke material construction shall be minimum equivalent to body / bonnet material.

5.1.21 Stem shall be of “Forged” material. No casting is permitted.

5.1.22 Full compliance with ASTM A961 section 6 is required for forged parts. Repair by welding is not

allowed.

5.1.23 For all the castings, product marking shall be as per ASTM A703. Single painted identification

marking shall not be accepted.

5.1.24 The steel melt shall be refined with AOD (Argon-Oxygen-Decarburization) for Stainless Steel,

Duplex and Nickel based alloy castings.

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5.1.25 Casting repair by no other than casting manufacturer is accepted with the following activities to

be mandatory achieved before any repair

Identification of the defects and method.

Method for removal of defects.

Limitations in acceptance of the defects.

Method of NDE before repair, WPS and PQR.

NDE acceptance criteria is based upon the main applicable standards, i.e. ASTM material standards, ASME B16.34 Standard (section 8.4), requirements of ASME V in addition to all the other applicable standards and codes whichever is the most stringent.

Traceability of the above activities including those of repair

5.1.26 In severe sour service, repair welding shall be limited to minor defects. Major repair welding is not permitted in Sour services. All weld repairs shall be approved prior to welding being carried out. Major repairs are defined in supplementary requirement S20 of ASTM A 703. In the single body valve, overall defect area shall not exceed the S20. However subsequent to any welding, the whole piece shall be heat treated.

5.1.27 Austenitic stainless steel and nickel alloy valves (body, bonnet, cover, and cap) shall meet the

following requirements:

Trim including stem and seats, gland assemblies including gland bolting, and trunnion support materials shall be of the same nominal chemistry as the body. Hard facing equal to CoCr-A shall be provided for seating surfaces when specified in the data sheet and is always an acceptable alternative seating surface.

Note: Hard facing (equal to CoCr-A) includes such trademarked materials as Stellite 6,

Stoody 6 and Wallex 6.

Bonnet and cover bolting material for valves NPS 3 and larger shall be specified and shall be of the same material specification as the bolting used for connecting piping.

5.1.28 Austenitic stainless-steel valve castings that have been subjected to weld repairs shall be

solution heat treated.

5.1.29 Weld repair qualification shall be performed carrying out heat treatment, Non-Destructive

Examination and Charpy V-Notch impact testing and hardness testing on the base material.

5.1.30 Cast material cannot be proposed as substitute to forged material.

5.1.31 If overlay is required, overlay thickness shall be sufficient to obtain a minimum of 3 mm thick

protective layer in the final machined condition (-0 / +1 mm of thickness tolerance).

5.1.32 Deleted.

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5.1.33 When required in the valve data sheets, seats and ball contact faces of metal seated ball valves shall be Tungsten Carbide coated. The thickness of the Tungsten Carbide coating, after grinding and lapping, shall be equal to 400 µm minimum. The minimum hardness shall be 1050 HV. Coating process shall be HVOF (High Velocity Oxygen Fuel).

5.1.34 Valve body materials are defined based on the pipe material while the material of internals (trim)

is established according to the fluids conveyed and the service required.

5.1.35 As a general principle, it can be laid down that the seal material shall be non-corrosive and that it shall have a higher grade of surface hardness than the plug-in order to avoid, as far as possible, erosion phenomena. Please refer to the below paragraphs.

5.1.36 All pressure containing components for forged Austenitic SS type 316/316L material shall undergo an lntergranular Corrosion (lGC) test in accordance with ASTM A262: “Standard Practices for Detecting Susceptibility to lntergranular Attack in Austenitic Stainless Steels”, practice E unless specified otherwise in the contract or PO.

5.1.37 304 Stainless steels shall not be used in any valve components (i.e., Wetted or Non-wetted,

Including nuts, bolts and washers) Offshore.

5.2

Non-Metallic Materials in Sour Service

5.2.1 Non-metallic seals such as elastomers and thermoplastics may be used for sours service process systems and are also subject to H2S limits. ISO 23936-1 and ISO 23936-2 provide the requirements for qualification for Thermoplastics and Elastomers items respectively.

5.2.2 All non-metallics used in process services shall be compatible with that of the hydrocarbon fluid. All elastomers used shall also be resistant to explosive decompression, also known as Rapid Gas Decompression (RGD). Hydrocarbon fluids may also include corrosion inhibitors containing amines, methanol and glycol (type of CI depend on advice from selected CI vendor).

5.2.3 The compatibility of the non-metallics used in NFPS production fluid service shall be verified in exposure tests involving all of the fluids and chemicals and including pressure, pressure cycles, temperature, and temperature cycles that simulate those expected over the service life of the component.

5.2.4 All non-metallics used in process services shall be tested in accordance with APPENDIX A & B of this document. Testing and qualification should take into account the specifications and limits established by the VENDOR.

5.2.5 The VENDOR shall propose elastomers suitable for the chemicals they would be exposed to in

this project.

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5.3 Elastomers

Elastomers are selected for seals; their selection shall be based on limitations in terms of chemical compatibility and design requirements. Indications about the suitability of some Elastomers in oil & gas production conditions are listed in the Appendices 3 of the Material Selection Philosophy for CP6S & CP7S Complexes (200-20-CE-DEC-00003) with more specific indications on the suitability of several commonly used Elastomer grades in sour service, available in Table A3-1, Section 10.

The equipment supplier shall be consulted with respect to elastomer recommendations (and supporting test data and service experience) for the project service conditions. These service conditions need to be clearly identified for this selection process.

5.4 Thermoplastics

No Poly Vinyl Chloride (PVC) is specified for items in sour service systems. Thermoplastics such as Polyphenylene Sulphide (PPS), Polyether Ether Ketone (PEEK) and Polytetrafluoroethylene (PTFE) can be used as seals. An indication of the limitations for the selection of the most common Thermoplastics is listed in in oil & gas production conditions are listed in the Appendices of the Material Selection Philosophy (200-20-CE-DEC-00003) with more specific indications on the suitability of several commonly used Thermoplastic grades in sour service, available in Table A3- 2, Section 10.

5.5 Non-Metallic Sour Service Limitations

The following Table 5.1. indicates the suitability and the limitations of non-metallic material in Sour Service.

Table 5.1 Non-Metallic Material Suitability for Sour Service

Non-Metallic Material

Type

Grade

Elastomers

Nitrile Butadiene Rubber

Hydrogenated Nitrile Butadiene Rubber

Fluoroelastomer - “Viton” type

Commercial Symbol

NBR

HNBR

FKM

Fluoroelastomer - “Viton Extreme” type

FEPM-TFE/P

Fluoroelastomer - “Aflas” type

FEPM-ETP

Perfluoroelastomer - “Chemraz or Kalrez” Type (3)

Thermoplastics

Ethylene Propylene (4)

Polyphenylene Sulphide

Polyether Ether Ketone

Polytetrafluoroethylene (5)

FFKM

EPDM

PPS

PEEK

PTFE

Suitability

Not Suitable

Not Suitable

Suitable (2)

Suitable

Suitable

Suitable

Requires Qualification

Suitable

Suitable

Suitable

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Notes: (1)

Delete. FKM Viton type seals may show embrittlement due to H2S induced vulcanisation effects and are subject to attack by high pH solutions and amine-containing inhibitors. O-rings are available in one piece up to 500mm diameter. Larger sizes without splice joints are available by special order only. Susceptible to Rapid Gas Decompression (RGD) and may not be acceptable with liquid hydrocarbons. Plastic flow under shearing stress shall be considered.

(2)

(3)

(4)

(5)

5.6 Seat Seals

5.6.1 All elastomer and/or non-metallic seal materials selection requires COMPANY approval and shall

meet the below requirements:

All elastomers and thermoplastics shall be suitable for the chemical environment, temperature range, and pressure in which they will operate.

In Class 300 and higher process service (design pressures > 40 barg), elastomers shall be resistant to explosive decompression (ED) as might be caused by high pressure gas, especially in the presence of carbon dioxide.

Table 5.2 lists temperature limitations for common seal materials

Table 5.2 Temperature Limitations for Common Seal Materials

Seal Material

Temperature Limit

Unreinforced PTFE (PTFE)

-200 to 205 °C (-328 to 400 °F)

Glass-reinforced PTFE (RPTFE)

-200 to 232 °C (-328 to 450 °F)

Nitrile (Buna-N)

HNBR

EPDM

PEEK

-30 to 120 °C (-22 to 250 °F)

-23 to 135 °C (-10 to 275 °F)

-51 to 150 °C (-60 to 300 °F)

-60 to 260 °C (-75 to 500 °F)

Most Viton materials

177 °C (350 °F)

5.6.2 Ball valve seats of modified PTFE (MPTFE, also known as TFM) or PEEK are an acceptable substitute where PTFE and reinforced PTFE (RPTFE) is specified, provided the pressure and temperature rating meets or exceeds the requirements specified.

5.6.3 All soft seated valves, (or) valves employing elastomeric body seals, that are to be welded into the line shall be provided with sufficient body extensions (or) welded-on pipes to allow field welding and PWHT, if specified, without disassembly, distortion (or) damage to non-metallic internals. The material of the extension shall be forged (or) cast as a part of the body or shall be welded-on with comparable pipe material. Such extension shall suit the connecting pipe wall thickness. The extension length and thickness shall be provided part of the quote for COMPANY approval. Pressure testing shall be performed after welding and heat treatment.

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5.6.4 Electroless Nickel Plating (ENP) on valve components shall comply with ASTM B733 and the

following Coating Classifications:

Table 5.3 ENP Coating Requirement

Substrate

Carbon & Low-alloy Steel

Austenitic Stainless Steel

Deposit Alloy Type

IV or V

Service Conditions

SC3 or SC4

Post Heat Treatment Class

2 or 3

III or IV

SC2 or SC3

3

5.6.5 Elastomer material is prohibited for the manufacturing of seat insert.

5.6.6 When specified, threaded connections to the body shall be seal welded. Injection fittings are an

exception and shall not be seal welded.

5.7 Stem Seals and Packing

5.7.1 Asbestos shall not be used for valve packing material.

5.7.2 Flexible graphite for packing and gaskets shall be corrosion inhibited, with a 98% minimum purity,

and 50 ppm maximum leachable chlorides.

5.7.3 Valve packing/stem seal material for “sliding-stem” valves (for example, gate and globe) shall be flexible graphite. The packing configuration shall consist of two end retainer rings made of braided graphite and three intermediate rings made from die-formed flexible graphite with a density of 1120 kg/m3 to 1280 kg/m3.

5.7.4 Valve packing/stem seal material for “rotary-stem” valves (for example, ball, and butterfly valves) used in combustible, dangerous, or toxic service shall satisfy the fire test requirements of API STD 607, API SPEC 6FA, or BSI BS EN ISO 10497. Additionally, the stem seal design and materials shall minimize fugitive emissions. Fugitive emissions test shall be Class B to ISO 15848 Part 1 and 2, and the manufacturer shall submit the certificates for COMPANY approval. Thermoplastic and/or elastomer packing/seals shall be used in Category D or in certain chemical services if the valve design has a backup fire-resistant stem seal that has passed fire tests requirements.

5.7.5 Except as permitted in Section 5.7.4, thermoplastic and/or elastomer packing shall only be used in non-combustible, non-flammable, and non-toxic services or in certain chemical services when approved by COMPANY.

5.7.6 The use of a spring-assisted packing gland design (e.g., Belleville spring washers) is not normally required. However, this design could be considered for use in certain applications (e.g., toxic services, frequent cycling, fugitive emissions sensitivities, etc.) to improve the life of the packing material.

5.7.7 Valves for services below -46 ºC (-50 ºF) operating temperature require extended bonnets to prevent freezing of gland packing/stem seal (renders the valve inoperable and/or results in process fluid leakage) as follows:

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a) For operating temperatures below -100 ºC (-150 ºF), all valves shall be of the extended bonnet/stem type with sufficient bonnet length to maintain the gland packing/stem seal near ambient temperature.

b) For operating temperatures between -46 ºC (-50 ºF) and -100 ºC (-150 ºF), valves shall be of the extended bonnet/stem type if they are required to be operational at the low temperature. The gland packing/stem seal at operating temperature shall not experience “icing” conditions.

c) The requirements for extended bonnet valves are not normally necessary for valves in flare and blowdown discharge pipe systems that are normally sealed open, since the valves will not need to be closed during a flare event.

d) The minimum extended bonnet length shall be in accordance with one of the specifications BSI BS EN ISO 28921-1, MSS SP-134 or BSI BS 6364, EEMUA 192 subjected to COMPANY approval.

e) Use of a drip/collar plate shall be considered for insulated valves.

5.7.8 Non-metallic seal materials, including Elastomers (Section 0) and Thermoplastics (Section 5.4), shall comply with. They shall be suitable for the chemical environment, temperature, and pressure in which they will operate. The materials shall be shown to exhibit the characteristics described in the Material Selection Philosophy 200-20-CE-DEC-00001, including Resistance to Explosive Decompression (ED) and suitability to Sour Service as per Table 5.1

5.7.9 All trunnion mounted ball valves shall be equipped with sealant and/or lubricant injection ports, the springs and check balls used in the injection ports shall be of a metallurgy comparable to that of the valve trim and suitable for the intended process fluid service. All injection ports shall be equipped with caps. Unless COMPANY approves otherwise, Sealant / lubricant / flushing injection fittings assemblies shall be provided for the seat and stem seal areas. The auxiliary fittings used for injection assemblies shall consist of a two check valves, primary Check valve within the valve body (spring loaded). And another check valve in injection fitting that shall be capped off. The internal check valve size shall be NPS 1/4 minimum. The threads shall be protected from the process fluid by a seal and there shall be at least one fire safe seal.

5.7.10 Structural grade steels (pipe, plate, or sheet) shall not be used for pressure-containing parts.

5.8 Gaskets

Ring joint gasket materials shall be selected in accordance with project “Specification For Bolts, Nuts and Gaskets for Topside Piping” Doc. No.:200-20-PI-SPC-00009. They shall be suitable for the chemical environment, temperature, and pressure in which they will operate. The minimum sour service suitable materials:

1. For Carbon Steel lines (Dry Gas Export), gasket will be based on 316L SS windings with

graphite filler.

2. For Carbon Steel lines with Alloy 625 Clad and Alloy 625 lines, gasket will be based on Alloy

625 (UNS N06625).

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6 DESIGN AND ENGINEERING REQUIREMENTS

6.1 General

6.1.1 The design life shall be 30 years minimum for all new and upgraded Facilities associated with the

services.

6.1.2 All valves shall be in accordance with this specification, and applicable Valve Datasheets.

6.1.3 Valve design shall meet the requirements of ASME B16.34 and as per the requirements stated

in the applicable valve datasheets.

6.1.4 Valves in combustible, flammable, or toxic services shall be certified as fire-safe, or shall be a

fire-safe design, regardless of operating temperature. Requirements are as follows:

1. All soft-seated valves in such services shall meet the fire-safe requirements, when fire-safe valves are specified, they shall be certified per API STD 607, API SPEC 6FA, or BSI BS EN ISO 10497.

2. Metal-seated valves in such services shall meet the fire-safe requirements of API SPEC

6FA or BSI BS EN ISO 10497.

3. If the same exact valve design is certified as fire-safe in its soft seat configuration (or within size/pressure class ranges permitted by applicable standard), then the valve design employing metal seats, shall be considered as a fire-safe design if it is identical to the soft seated version in all aspects, including the stem seal. No additional fire testing is required.

4. Metal-seated valves, such as conventional (non-expanding and non-slab) gate, globe, and check valves, with only graphite or metal ring, and no thermoplastic or elastomer packing, gaskets, seats, or seals, are considered as inherently fire safe (fire-safe design). No additional fire testing is required.

6.1.5 Deleted.

6.1.6 Valves with non-welded threaded body joints (such as a 2-piece mid-entry valve or a 3-piece valve with a body that has threaded tailpieces) that could leak to the atmosphere or be inadvertently disassembled, are not permitted in any fluid service at any pressure.

6.1.7 Valve stems and check valve/butterfly valve shafts shall be blowout proof if the stem or shaft becomes separated from the closure device, if the stem nut becomes detached from the yoke, or if the packing gland is removed. Valve stems shall be designed such that the weakest link is outside of the pressure boundary. Packing glands shall not be used to provide this protection.

6.1.8 Flanged valves shall be provided with flanges that are integrally cast or forged with the body.

Welded-on flanges or hubs are not permitted.

6.1.9 Forged, extended-body valves shall have the extension integrally forged with the body. Welded-

on extensions are not permitted.

6.1.10 Valves with thread body joints (e.g., threaded body ball valves) are not permitted unless the

valves are secured together (e.g., by seal welding) by the valve manufacturer.

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6.1.11 Piping, fittings, and valves for integral bypasses and bleeds shall meet the pressure/temperature ratings of the parent valve. The pipe and fitting materials shall be seamless, and of the same basic materials as the parent valve. Pipe and fitting thickness shall be specified as part of the order. Attachment locations to the parent valve shall be made in accordance with ASME B16.34.

6.1.12 Valve body bleeds shall be NPS ½ or larger and shall be roddable for cleaning.

6.1.13 Number of auxiliary connections on the valve body shall be minimized.

6.1.14 Lifting lug & supports on the valves are not recommended to be pinned from the body bolting.

But recommended that these are to be independent of body bolting.

6.1.15 Orientation of the lifting lugs on the valves shall be suitable for the lifting the valve from the installed location (special attention shall be provided for the valves installed in vertical and other angular orientations).

6.1.16 Unless otherwise agreed with COMPANY, valves shall be fully rated in accordance with the rating tables of ASME B16.34 or other design codes as indicated in the valve data sheet.

6.1.17 Bolting, including calculations, shall satisfy the ASME B16.34 requirements. Vendor shall provide calculation for review. Bolting threads shall be in accordance with the “Coarse” series, for diameter less than or equal to 1 in. “8UN thread” Series for diameters equal to or greater than 1 1/8 in, The machining surface condition tolerances applicable to the various threading shall be in conformity with the following classes.

1. Class 2A of standard ASME B1.1 for Stud bolts, Headed (Machine) Bolts.

2. Class 2B of standard ASME B1.1 for nuts.

6.1.18 Cavity bleed/vent connections shall be a threaded (NPT) plug where the thread is protected by

an O-ring above and below the thread.

6.2

Cavity Relief

Acceptable forms of cavity overpressure protection devices include the following:

a.

Self-relieving seats such as single-piston-effect seats for trunnion-mounted ball valves.

Spring loaded check valves meeting the following:

The maximum differential required to open the check valve shall not exceed 5% of the pressure rating of the valve body.

Drilling one side of a floating ball or gate valve wedge for thermal relief protection of the valve cavity shall only be used with Company approval. A single ball or gate valve with a hole drilled on the ball/wedge will become a unidirectional valve. Where such valves are permitted, measures shall be put in place to avoid accidental reversal of the valve during installation and/or improper use for isolation. The valve shall meet the requirements for uni-directional valves.

6.3 Wafer And Wafer Lug Valves

6.3.1 Wafer or wafer lug type valves are only permitted in Category D fluid services (as defined by

ASME B31.3) but are not permitted in fire-water systems.

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6.3.2 Wafer or wafer lug type valves shall not be used as the first block valve against storage tanks or

vessels in any fluid service.

6.3.3 The maximum permissible length of exposed bolt threads caused by a wafer-type valve or device is 76 mm (3 in.). The use of thin-walled flange bands alone shall not be considered as adequate enough to fully mitigate the concern.

6.3.4 Check valves shall be wafer lug type with drilled-through holes (not tapped), have a full diameter body (OD body = flange OD) with drilled-through holes, or shall be double flanged. Double flanged valves shall be used in sizes where they are available (generally NPS 12 and larger).

6.4 Gate Valves

6.4.1 Carbon steel gate valves shall be in accordance with the following:

NPS 1 ½ and smaller steel gate valves shall conform to API STD 602 or BSI BS EN ISO 15761.

Size NPS 2 flanged end steel gate valves shall conform to API STD 600, API STD 602, or BSI BS EN ISO 15761.

NPS 3 and larger wedge type carbon steel gate valves shall conform to API STD 600.

6.4.2 Gate valves in stainless steel and other corrosion-resistant materials shall conform to ASME

B16.34, API STD 602, or BSI BS EN ISO 15761.

6.4.3 When specified for applications with corrosion allowance greater than 2.5mm (0.1in), cast valves in stainless steel and other corrosion-resistant material, valves shall meet API STD 600 for wall thickness.

6.4.4 Flexible, one-piece wedges shall be used for NPS 6 and larger. NPS 4 and smaller gate valves

shall be solid wedges.

6.4.5 All gate valves shall be designed to be suitable for both vertical and horizontal Installation without

binding of the gate during operation.

6.5 Ball Valves

6.5.1 Selection of ball valves shall be as follows:

Ball valves Class 150 and 300 up to NPS 6 (or NPS 8, if reduced port type) shall be floating type per API STD 608 (NPS ½ to 1 ½) and API SPEC 6D (NPS 2 and above). Larger sizes shall be trunnion mounted per API SPEC 6D.

Ball valves Class 600 and higher, NPS 1 ½ and smaller, shall be floating type per API STD 608. NPS 2 and larger shall be trunnion mounted per API SPEC 6D.

All actuated ball valve shall be trunnion mounted as per API SPEC 6D.

6.5.2 Unless otherwise specified in the valve data sheets, valves with soft seat shall have bi-directional

shutoff.

6.5.3 Ball valve design shall include the Anti-static requirements and blowout-proof stems.

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6.5.4 Balls and stems in ball valves shall be solid material. Hollow ball design is not permitted for any

application.

6.5.5 When required in the valve data sheets, internal parts of valves shall be Electroless Nickel Plated in accordance with ASTM B733. The minimum coating thickness shall be 75 µm (SC4), For NPS 6 and larger, use of valves with electro less-nickel plated (ENP) balls is only permissible with COMPANY approval. ENP is not permitted in abrasive, corrosive, or sour service applications.

6.5.6 Ball valves shall not be used in throttling service unless specifically designed for throttling by the

Manufacturer.

6.5.7 Ball valves constructed so that the ball is held in place with a threaded portion of the valve body (e.g., threaded body valves) are not permitted unless the valve halves are positively secured together (i.e., by seal-welding) by Valve Manufacturer.

6.5.8 Additionally, plugs in threaded body openings shall be wrought (not cast) material. Plugs shall be solid, hex head, having comparable material as the body except where the body is clad/overlay material, in which case the plug shall match the clad/overlay material.

6.5.9 Deleted.

6.5.10 Cast material is not allowed for valve stem and ball regardless of the pressure class and valve

size.

6.5.11 Vendor drawings or documentation shall be provided that reflect the type of seat used on each ball valve supplied. The information shall include the type of upstream and downstream seat (self-relieving single-piston effect or double-piston effect) by unique valve tag number or serial number. If self-relieving seats are specified, Manufacturer shall submit documentation certifying that the design of the cavity relief system has been proven to be acceptable over the entire temperature range specified for the valve (including the lowest temperatures).

6.5.12 Seal welds, if any, shall be dye penetrant examined; Seal welds are not allowed on carbon steel

valves when used in sour service.

6.5.13 Deleted.

6.5.14 The bore of reduced bore ball valves shall as follow:

a) All Reduced Bore Ball Valves up to 24” size shall be supplied as per API 6D.

b) All Reduced Bore Ball Valves above 24” size shall be supplied with bore size reduced to

maximum 2 size (4”). Refer below Table 6.1 for reference.

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Table 6.1: Minimum Bore Size for Reduced Bore Manual Ball Valves

Valve Body Size

Bore Size

26”

28”

30”

32”

34”

26” x 22”

28” x 24”

30” x 26”

32” x 28”

34” x 30”

6.5.15 The ball shall be capable of withstanding the maximum differential pressure, in either flow direction, as per the appropriate class. The seat design and materials shall be able of the quarter turn operations (full stroking from opening to closing and vice versa) under a differential pressure equal to the maximum design pressure as per appropriate class with full integrity of the valve tightness level attached to the imposed leakage rates.

6.5.16 An integral ball/stem design for seat supported (floating) ball is not acceptable.

6.5.17 All the metal seated ball valves shall be of a trunnion mounted design.

6.5.18 A pressure relief hole or equalizing pressure hole in the ball is not allowed, whether on floating

ball or on trunnion mounted valves.

6.5.19 Top-entry ball valves shall be with butt welding ends and Top-entry ball valves greater than 10” shall be delivered with necessary tools for dismantling of all valve internals, with the valve in the installed position.

6.5.20 Soft seated ball valves with butt welding end shall be provided with extension pup pieces which shall be considered as an integral part of the valve. The pup piece shall be either one piece with the body or welded to the valve before the valve internals are installed, and the lengths shall be as follows:

1. For valves DN 200 to DN 400 (NPS 8 to NPS 16): 400 mm

2. For valves ≥ DN 450 (≥ NPS 18): 800 mm

6.5.21 Trunnion supported valves, NPS 8 inch and larger, shall have a seat sealant injection system or other secondary means to achieve a seal in emergency cases. When a seat sealant injection fitting is required, a check valve shall be installed in the valve body wall under the sealant injection fitting.

6.5.22 Pipeline Valve Requirements

1. All Ball valves shall be with Top Entry design.

2. All Ball valves shall be with butt welding ends.

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3. Short pattern ball valves shall not be permitted.

4. The obturator shall be solid one-piece forging and shall be trunnion mounted. The ball port

shall be cylindrical.

5. Full bore ball valve shall be capable of being pigged, sphered and scraped regularly without damage to the valve seat. The bore of the valve in the open position shall present as smooth profile as possible to allow passing of all type of launched pigs or scraper.

6. Full bore valves for pigging shall be designed such that the bore ID shall match with the respective pipeline ID. The full length bore ID of the valve shall be verified during FAT through “drift tool test”.

6.6 Check Valves

6.6.1.1 For lines that do not require pigging, selection of check valves shall be as follows:

1. For sizes larger than NPS 2, the preferred type of check valve in general services is a double-flanged or lugged, retainer less, dual-plate style check valve, per API STD 594.

2. Swing checks are permitted and shall be in accordance with the following:

a) Carbon steel NPS 1 ½ and smaller shall conform to API STD 602 or BSI BS EN ISO

b) Carbon steel NPS 2 shall conform to API STD 600, API STD 602, or BSI BS EN ISO

c) Carbon steel NPS 3 and larger shall conform to API STD 600 or API SPEC 6D.

d) Stainless steel and other corrosion-resistant materials shall conform to API STD 602, ASME B16.34, or BSI BS EN ISO 15761. Swing check valves built to ASME B16.34 require checking to ensure the valve can withstand the maximum differential pressure.

3. For valves NPS 2 and smaller, spring-assisted piston-type check valves are permitted that conform to API STD 602, ASME B16.34 or BSI BS EN ISO 15761. Design shall suit for both horizontal / vertical installations. For fire water service for sizes below 2” Y-pattern swing check valves shall be used.

In pipe or tubing sizes smaller than NPS ¾, including “in-line” check valves, spring loaded ball type check valves are permitted in clean, solids-free, noncorrosive services with low viscosity fluids.

6.6.2

6.6.3

6.6.4

Dual-plate type check valves in hydrocarbon service shall be the “pin retainer less” design. The design shall be of the type where the internal pin-retaining mechanism does not intrude into the gasket sealing element surface.

Dual-plate check valves shall be designed for installation in the horizontal or vertical up flow positions.

CONTRACTOR shall ensure the minimum required velocity to keep the check valve fully open is maintained while the line is operating. For services where the flow rate in the line varies, the minimum velocity shall be met at the minimum flow rate expected during normal operations and minimum the maximum velocity recommended by the Check Valve Manufacturer is not exceeded at the maximum flow rate expected during normal operations. CONTRACTOR shall notify COMPANY for any instance

turndown. CONTRACTOR shall also ensure

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where either the minimum required velocity or the maximum velocity does not comply with Manufacturer’s recommendations.

The body of the Dual Plate Check valve shall integrate a feature to detect the hinge pin position in the installed condition.

Refer Additional Requirements and Restrictions of Section 6.3 of this specification for Wafer type valves

6.6.5

6.6.6

6.7 Globe Valves

6.7.1 Globe valves shall confirm to ASME B16.34 and in accordance with the following:

1. NPS 1 ½ and smaller shall conform to API STD 602, ASME B16.34 or BSI BS EN ISO 15761.

2. NPS 2 shall conform to API STD 600, API STD 602, API STD 623, or BSI BS EN ISO 15761.

3. NPS 3 and larger shall conform to API STD 600 or API STD 623.

6.7.2 If the pressure drop across a globe valve exceeds 50% of the upstream pressure, the disc shall be wing guided or of the “V” port pattern. Plug type discs shall be used up to NPS 2. If the pressure drop is less than 50%, conventional disc-type valves are acceptable.

6.7.3 Globe valves shall be suitable for re-packing under pressure in the fully open position.

6.7.4 Globe valves shall have a conical or spherical back seat in the bonnet.

6.7.5 Seats of Globe valves 2” and larger shall be removable.

6.7.6 The body-bonnet gasket is spiral-wound; when the valve rating is ≥ 900#, the body-bonnet gasket

is RJ. If pressure seals are used, the gasket is defined by the Manufacturer.

6.8 Butterfly Valves

6.8.1 Butterfly valves shall meet API STD 609, Category B.

6.8.2 Butterfly valves shall be used in pressure classes up to Class 900. Higher pressure applications are only permitted with COMPANY’s approval after review of the specific application and intended purpose. Such approvals require a documented reliability assessment for the valve and its actuator. Butterfly valves shall not be used in Hydrocarbon service.

6.8.3 Butterfly valves used for throttling service shall meet the following:

1. As a minimum, the valve shall be of the double offset design.

2. Butterfly valves in Fiberglass-Reinforced Plastic (FRP) and other non- metallic piping systems are not permitted in throttling services unless a metallic liner is installed immediately downstream of the butterfly disc for a length that would be specified by the CONTRACTOR during the course of design.

6.8.4 Soft-seated butterfly valves larger than NPS 4 shall NOT be used as the first block valve for the holdup of large volumes of combustible, flammable, or toxic materials (> 38,000 L liquid holdup).

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6.8.5 Butterfly valves shall be the double-flanged type in fire-water service. In smaller sizes, where double-flanged type valves are not manufactured, they shall be the lug-type with drilled-through holes (not tapped). See limitations on wafer lug-type valves in Section 6.3

6.8.6 Butterfly valves shall be designed for the full rated class pressure.

6.8.7 Butterfly valve stem shall be designed with a permanent indicator (pin, casting, line, etc., painting is not permitted) marked on the valve stem and visible with the actuator (or) gearbox installed, which indicates the true open and close position of the disk. A gearbox operation with this indicator is not sufficient.

6.8.8 Triple Offset Valves (TOVs) shall meet the following design requirements in order to be used as

isolation valves:

1. Valves are recommended to have a replaceable disc seal ring design. The use of laminated

seal rings is recommended for non-cryogenic services.

2. Valves shall meet positive tight shutoff requirements.

3. The shaft-to-disc connection shall be a proven design with a documented history of at least

5 years of reliable service.

4. Valves shall employ some form of mechanism (safety wire, staking, etc.) to ensure the disc-

to-seal retainer flange bolts do not come loose.

5. Valve actuators shall be sized with a 50% closing torque safety factor. The 50% safety factor will encompass all Vendor design factors over the maximum required shutoff torque (total actuator torque shall not exceed 150% of actual valve closure torque).

If the valve gearbox or actuator is removed during shipping, Manufacturer or a Qualified Specialist shall reset the valve’s actuator to the valve body orientation in the field.

6.8.9 Where data sheets for Butterfly valves indicate the inside diameter of connecting pipework. VENDOR shall confirm in his bid that the mating pipe work bore shall give adequate disc swing clearance.

6.8.10 Butterfly valves shall be provided with integral shouldered shaft to prevent shaft/stem blowouts

and to ensure precise positioning of disc.

6.8.11 Gasket facings on the valve shall not be affected by bolts or fixing screws. Seat retainers should be self-supporting and not rely on the clamping flanges for seat retention, etc. Machine bolts on the butterfly valves around the stem areas shall be supplied by the valve manufacturer.

6.8.12 Disc-to-Shaft attachment shall not rely on friction alone (e.g.,rolled pins, tapered pins, and threaded fasteners) but shall be positively mechanically locked in place (e.g., peened, tack welded, safety wired).

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6.9 Double Block and Bleed Valves

6.9.1 IDBB (Isolation Double Block & Bleed) valves shall be in according to all the points of Section.

6.5 and the below points:

IDBB shall be three-piece construction.

Bleed connection shall be 1” Ball full bore flanged end for In line DBB arrangements.

6.9.2 For on-line instrumentation isolation Compact DBB shall be used, Compact DBB shall be with ball as isolation valves & needle as bleed valve and shall be according to the below points:

a)

b)

c)

Forged construction, type OS&Y (Outside Screw and Yoke).

Minimum internal bore shall be 5mm.

Bleed connection shall be 0.5” Needle valve shall be flanged end for Online DBB arrangements. (used only for instrument connections)

d)

Flanged end shall be according with ASME B16.5.

6.10 Valve Operators - Lever and Hand Wheel

6.10.1 Levers for manual valves shall be sized so that a force of no more than 14 kg (30 lbs) on the end

of the lever (assuming one handed operation) will open or close the valve.

6.10.2 All manually operated valves shall be provided complete with handle/hand wheel. The maximum lever length shall be the lesser of three times the face-to-face length of the valve body or 500 mm (20 in.). Levers longer than three times the face-to-face length of the valve body shall be so as not to obstruct aisle pathways. If lever length becomes a concern, consideration shall be given to use of oval type hand wheels.

6.10.3 Hand wheels for manual (gear reduction or direct drive) valves shall be sized based on the hand

wheel force required to operate the valve as listed in Table 6.1.

6.10.4 Gear operators shall be heavy duty type and shall be completely housed in a weatherproof enclosure. Gear operators shall be used when necessary to meet the maximum permitted force criteria.

Table 6.1 Hand Wheel Forces for Manually Operated Valves

Hand wheel Diameter Range (2)(4)

Maximum Force (1)(3)

Small Hand wheel Diameter

≤180 mm (:5 7 in.)

2.3 kg (5 lbs) total rim pull (assumes two-

handed operation)

Large Hand wheel Diameter

455 mm (18 in.) and larger

23 kg (50 lbs) total rim pull (assumes two-

handed operation)

Notes:

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(1)

Forces for hand wheel diameters between the size ranges shown shall be interpolated.

(2)

(3)

(4)

For valves larger than 50 mm (2 in.) NPS, the hand wheel diameter shall not exceed the lesser of either the valve face-to-face (end-to-end) dimension or 1000 mm (39 in.). The Valve Manufacturer’s standard hand wheel diameter is acceptable for valve sizes 50 mm (2 in.) NPS and smaller.

Forces shown represent the valve’s normal turning force. Valve’s initial “breakaway” force shall not exceed the lesser of either twice the normal turning force or 36 kg (80 lbs) force.

Interpolation is permitted for hand wheel diameters between the sizes specified in this table.

6.10.5 Impact wheels shall not be used on valves made of cast iron or on valves with cast iron hand

wheels. Impact wheels shall not be used on quarter-turn valves.

6.10.6 For NPS 2 and smaller, where a lever is specified, oval type hand wheels shall be substituted

with prior approval from COMPANY.

6.10.7 All quarter-turn lever or oval hand-wheel operated valves without gear operators, or any other valves without multi-turn hand wheels, shall include a locking mechanism capable of locking the valve in the open or closed position.

6.10.8 All valves shall be provided with Pad lock and use of chains for locking is not permitted and shall

be suitable for installing car seal open (CSO) & car seal close (CSC) arrangement.

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6.11 Valve Operators – Gear

6.11.1 A gear operator shall be provided for the sizes listed in Table 6.2. Sizes smaller than those shown shall be hand wheel/lever operated, provided the torque to break open or close the valve at maximum differential pressure does not exceed the criteria established in section 6.10.

Table 6.2 Minimum NPS Valve Size Requiring Gear Operator

ASME/API Class

Gate

Globe

Ball (Floating)

Ball (Floating)

Ball (Trunnion)

Ball (Trunnion)

Reduce Bore

Full Bore

Reduce Bore

Full Bore

Butterfly

ASME 150

ASME 300

ASME 600

ASME 900

ASME 1500

ASME 2500 /

API 5000

14

12

8

6

4

4

10

8

4

3

3

3

8

6

6

6

8

6

6

4

3

2

6

6

6

4

3

2

8

8

6

6.11.2 Gear operators shall be heavy duty type and shall be completely housed in a weatherproof

enclosure.

6.11.3 Trunnion ball valves typically have lower torque requirements when compared to the same sized

and pressure class valve in floating type.

6.11.4 Valve and gear operator design shall include provisions to prevent overpressure of the gear operator case should the valve leak process fluid through its stem seal. If pressure relief vents are installed on the gear operator case, provisions shall be included to prevent entry of debris and water into the gear case, thus contaminating the lubricant. Furthermore, the use of pressure relief vents should include provisions to ensure that the hole is not plugged by insects or debris.

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7

INSPECTION AND TESTING

7.1

General

7.1.1 All valves shall meet the inspection and examination requirements of ASME B16.34, and the applicable standard for the valve’s method of manufacture (i.e., cast, forged, welded, etc.) plus the additional requirements listed in this section.

7.1.2 Positive Material Identification (PMI) of alloy and stainless-steel valves shall be carried out according to Specification for Positive Material Identification (PMI) for CP6S and CP7S Complexes (Doc. No. 200-20-CE-SPC-00020).

7.1.3 All valves shall meet the minimum required shell and closure tests of API SPEC 6D, API STD

598, or the applicable standard as required by the applicable valve datasheet.

7.1.4 Prototype valve designs in process service shall be high and low pressure closure tested per the applicable standard, using air/nitrogen as described in section 7.1.6, in addition to the type testing for performance verification per Section 7.1.3. A valve shall be considered a prototype if any of the following apply:

Manufacturer has made significant changes to the standard design.

Manufacturing facility has no previous experience with the particular valve model.

Industry experience of less than 2 years with the valve design.

7.1.5 Quarter-turn valves shall be leak tested with the final gear operator installed.

7.1.6 Critical Valves as identified in the data sheets shall be high-pressure seat tested. Seat shall be conducted with air or nitrogen discharged slightly below water to facilitate determination of leakage rates.

7.1.7 All valves specified for Type B isolation service shall be high-pressure closure tested and double- isolation-and-bleed tested in accordance with API SPEC 6D (for API SPEC 6D valves) or API STD 598 (for all other valves). Testing shall be conducted with air/nitrogen as described in Section 1.1.2 above. Leakage shall be measured through the open bleed.

7.1.8 All valves specified for Type B isolation service shall be high-pressure closure tested and double- isolation-and-bleed tested in accordance with API SPEC 6D (for API SPEC 6D valves) or API STD 598 (for all other valves). Testing shall be conducted with air/nitrogen as described in Section 1.1.2 above. Leakage shall be measured through the open bleed.

7.1.9 Valve end to end dimension shall meet the requirements of ASME B16.10 or the applicable standard. End to end dimensions that do not comply with the applicable stamdard shall be identified in the quote for acceptance by COMPANY.

7.1.10 Flanged valves larger than NPS 24 shall use ASME B16.47 Series B flanges for 150# to 600#.

7.1.11 Flange-face imperfections shall meet the acceptance criteria of ASME B16.5 “Flange Facing Finish Imperfections” or ASME B16.47 “Flange Facing Finish Imperfections” as applicable.

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7.1.12 All flanged valves shall meet the flanged end tolerances of API SPEC 6D “Valve Ends”, including

bolt-hole misalignment.

7.1.13 All butt-welded valves end shall meet the requirements of ASME B16.25.

7.1.14 Vendor as a part of the offer shall submit the hydro test procedure for welded end valves for

COMPANY approval.

7.1.15 Vendor as a part of the offer shall submit the valve maintenance procedure for COMPANY

approval.

7.1.16 Process valves designed with elastomer seals and/or O-rings shall be proven through experience or testing for the service and design conditions (pressure/temperature range) for each type of valve construction offered by Manufacturer. Each seal material and configuration (seal groove size versus seal shape and groove fill) shall be verified for the specified service. When the Manufacturer does not have experience or test data to validate the design, it shall be “type tested” as follows:

The valve “type test” shall use the performance method and qualification range as per API SPEC 6A Annex F “Design Validation Procedures.” A modified API SPEC 6A Annex F performance test shall be acceptable, provided the proposed test procedure is approved by Company prior to use.

If the Manufacturer has no previous qualified project experience with the particular seal material and/or configuration, it shall be tested.

If the Manufacturer has made changes to the qualified design of the elastomer seal configuration and/or material (e.g., change in seat, stem or seal design configuration, materials, design parameters, etc.) it shall be retested.

7.1.17 All actuated valves shall have the pressure tests performed with the actuator mounted on the valve to ensure that the actuator settings (stops, etc.) are properly set and that mounting the actuator does not affect the stem seal.

7.1.18 All actuated valves shall be subjected to a functional test, with the actuator mounted on the valve. The function test shall use the intended actuator control system, unless waived by COMPANY, and shall demonstrate the adequacy of the actuator sizing, along with the time required to stroke the valve against its full rated design pressure differential.

7.2

Visual Examination

7.2.1 All the surface of casting shall be 100 % visually inspected as per MSS SP-55 (figures “b” shall

be used as reference of acceptance).

7.2.2 Finish and appearance of forgings shall meet the requirements of ASTM A961.

7.3

Pressure Tests

7.3.1 Unless otherwise specified, each valve (100% of the supply) shall be individually pressure tested

in accordance with standards mentioned in the following

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7.3.2 Leakage rate of tight shut-off metal seated valves shall be according to Table 5 of API

598.Edition 2016.

7.3.3 Valves shall be tested unpainted. Valves fitted with stem emergency sealant injection system, shall be pressure tested without any sealant material in the valve. The same requirement applies to valves with seat sealant injection systems.

7.3.4 All the drain, vent, bleeder, bypass or sealant injection (without or with extension) are integral part of the valve and shall be subjected to the pressure tests only when definitely mounted on the valve.

Table 7.1 Valve Pressure Tests

Shell test, liquid

Back Seat test

Low-pressure Closure (Seat) test, air or gas

Valve types

Required Yes/No

Standard to be applied

Required Yes/No

Standard to be applied

Required Yes/No

Standard to be applied

S E V L A V L L A B L E E T S

S E V L A V E T A G

For valves of API 6D design standard

For valves of ISO 17292 / API 608 Design standard

For valves of API 602 Design standard

For valves of API 600 Design standard

For valves of API 6D Design standard

Yes

API 6D

Not applicable

Not applicable

Yes, each

seat

Yes

API 598

Not applicable

Not applicable

Yes, each

seat

Yes

API 598

Yes

API 598

Yes

API 598

Yes

API 598

Yes

API 6D

Yes

API 6D

Yes, each

seat

Yes, each

seat

Yes, each

seat

Test pressures, duration as per API 6D. Acceptance criteria: ISO 5208 rate A for soft seated valves and rate D for metal seated valves

Test pressures, duration as per API 598. Acceptance criteria: Zero bubble as per API 598 for soft seated valves and as per table 6 of API 598 for metal seated valves.

API 598

API 598

Test pressures, duration as per API 6D Acceptance criteria: ISO 5208 rate D for metal seated valves.

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Shell test, liquid

Back Seat test

Low-pressure Closure (Seat) test, air or gas

Requir ed Yes/N o Yes

Standard to be applied

Required Yes/No

Standard to be applied

Required Yes/No

Standard to be applied

API 598

Yes

API 598

Yes, unidirectional

API 598

Yes

API 598

Yes

API 598

Yes, unidirectional

API 598

Yes

API 598

Not applicable

Not applicable

Yes, unidirectional

Yes

API 598

Not applicable

Not applicable

Yes, unidirectional

Yes

API 6D

Not applicable

Not applicable

Yes, unidirectional

Yes

EN 593, tests P10 & P11 of EN 12266-1

Not applicable

Not applicable

Yes, or as altern. the water seat of EN12266-1 can be achieved

API 598

API 598

Test pressures, duration as per API 6D. Acceptance criteria: ISO 5208 rate A for soft seated valves and rate D for metal seated valves

EN 593, test P12 of EN 12266-1

Yes

API 598

Not applicable

Not applicable

Yes, bidirectional

API 598

Yes

MSS SP 80

Not required

Not required

MSS SP 80

Yes, or as altern. the water seat of MSS SP-80 can be achieved

Valve types

For valves of API 602- Design standard

For valves of BS1873 Design standard

For valves of API 594 Design standard

For valves of API 602 Design standard Nozzle Check Valves designed as per API6D

For valves of EN 593 Design standard

For valves of API 609 Design standard

Valves of MSS SP- 80 Design standard

S E V L A V E B O L G

S E V L A V K C E H C

S E V L A V Y L F R E T T U B

&

,

E L G N A

,

E B O L G

,

E T A G E Z N O R B

S E V L A V K C E H C

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7.4 Test Medium

7.4.1 Water Test

1. Testing medium shall be clean, inhibited, fresh water and with pH between 6.5 and 8.5.

2. Stainless steel valves and valves fabricated with some parts made of stainless steel, shall be tested using inhibited fresh water having a maximum chloride content of 30 ppm. The temperature of the test medium must be a minimum of +10 degrees Celsius.

3. After testing, all valves shall be thoroughly dried to prevent possible corrosion from the

water.

7.4.2 Gas Test

1. Gas test shall be monitored using soap bubble method where zero leakage are either

expected or requested.

2. Where leak rates other than zero are specified, the leakage rate shall be measured using:

a)

Bubble box filled with water, with counting of air bubbles.

b) Measuring cylinder (calibrated burette) in a water tank with measuring a leak volume.

c) Gas flow meter (interconnected with a calibrated computer system with screen display

and results printed records and charts)

d)

Rota meter type flow meter for high leakage rates and large valve sizes with additional requirements for flow meters which shall be calibrated, relevant method with details of test apparatus to be submitted to prior approval by the COMPANY.

3. Measurement method shall be suitable with the acceptance criteria and shall be part of the

testing procedure to be submitted for COMPANY approval.

7.5 Supplementary Test Requirements

7.5.1 Torque/thrust functional testing

1. Each actuated valve is subject to a torque/thrust functional test as stipulated in clause H.6 of API 6D Edition 2015 and at the maximum differential pressure as specified in the Instrumentation data sheets.

2. One manual valve per purchase order item is subject to a torque/thrust functional test as stipulated in clause H.6 of API 6D Edition 2015 and at the maximum differential pressure corresponding to the nominal pressure of the valve pressure class. The same requirement is applicable to any item of purchase order amendment.

Test shall be completed with pressure applied on the first seat; the test shall be repeated with pressure applied to the opposite side.

7.5.2 Cavity relief testing

1. For each actuated ball valve of the same design, size, rating, material and seat arrangement, one valve is subject to a cavity relief test as stipulated in clause H.8 of API 6D Edition 2015. The same requirement applies for purchase order amendments.

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2. One manual ball valve of size 2” and larger per purchase order item is subject to a cavity relief test as stipulated in clause H.8 of API 6D Edition 2015. The same requirement is applicable to any item of purchase order amendments.

7.5.3 Functional Testing: with the valve fully assembled with its operating device, complete strokes shall be achieved (from full closed to fully open positions and vice versa) at the maximum differential pressure corresponding to the nominal pressure of the valve pressure class.

7.5.4 Fugitive Emission Testing (FET): All valves in Sour Service NACE shall be fugitive emission tested as per ISO 15848-2 class B. Initial percentage shall be 10% on the first 25% of the same lot, type, pressure class and size. If rejection rate is higher than 0 (zero) then, production FET shall be increased to 100% for the next 50% of the same lot, type, pressure class and size. If rejection rate is again higher than 0 (zero) then, production FET shall be maintained to 100% for the remaining 25% of the same lot, type, pressure class and size.

7.5.5 If the rejection rate of these 50% of the same lot, type, pressure class and size is 0 (zero) then FET testing shall be reduced to 10% of the same lot, type, pressure class and size for the remaining 25% of the valves ordered. If the rejection rate of the initial FET testing on the first 25% of the same lot, type, pressure class and size is 0 (zero) then FET testing can continue 10% of the next 50% of the same lot, type, pressure class and size.

7.6

Inspection Levels

7.6.1 Responsibility

1. Each valve shall be 100% individually tested by the Manufacturer in his shop and under his responsibility. CONTRACTOR’S inspection department shall not release any valves, unless all applicable certificates and / or documents have been submitted and approved.

100% of mandatory tests required by the applicable valve standard shall have been already completed by manufacturer before notification for inspection. The relevant test reports shall be available at the time of notification for inspection.

In addition to checking the certificates, CONTRACTOR’S inspection department shall check the quantities presented and shall have witnessed and / or checked the following:

a) The visual inspection is achieved by the manufacturer and CONTRACTOR’S Inspector in reference to the cross-section drawings, list of parts, detail drawings, general arrangement drawings which shall show and describe the actual manufacturing of the equipment.

b) Destructive tests called for in the codes and standards

c) Pressure tests

d) Special examinations

e) Workmanship

f) Nominal dimensions and dimensional tolerances

g) Protective coating and finish conditions

h) Marking and packing conditions

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7.7 Extent of Inspection and Witnessing

With regards to the above-mentioned responsibilities, the witness and inspection rate shall be as follow

Table 7.2 Extent of Inspection

Valve size (bore size for ball valves)

Butterfly Valves

Gate, Globe, Check Valves

Ball Valves

Metal seated

Soft seated

≤ 1 ½ ”

2” to10”

≥ 12”

N/A

10%

25%

Valves in pressure class B16.34

10%

25%

50%

25%

100%

100%

10%

25%

100%

Higher inspection / witnessing rates shall be required by COMPANY in specific cases (e.g., in case of test failures, oxygen service, etc.)

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8 PREPARATION FOR SHIPMENT

8.1 General

8.1.1 Compact and extended body gate and globe valves, and soft-sealed wafer-type butterfly valves, shall be in the closed position during shipment and subsequent storage. Other soft-sealed valves shall be shipped in the open position.

8.1.2 Valves, as well as associated operating mechanisms, shall be crated for shipment to protect

against internal and external damage.

8.2 Protective Coatings

8.2.1 Valves shall be protected according to 200-20-CE-SPC-00015 “Painting Specification for CP6S

& CP7S Complexes”.

8.2.2 Machined or threaded exterior surfaces of carbon steel, cast iron, ductile iron, and ferrous alloys with a nominal chemistry of 12 Cr and below shall be protected from corrosion during shipment and subsequent storage by coating with a rust preventive of a type as follows:

a)

To provide protection during outdoor storage, for a period of 12 months, exposed to a normal industrial environment.

b)

To be removable with mineral spirits or any Stoddard solvent.

8.3 Valve Protection

8.3.1 Covers for the protection of gasket surfaces of end flanges or body facings, and for the protection

of welding ends, shall be metal, hardboard, plastic, or solid wood.

8.3.2 Valves with threaded or socket welding ends shall have the ends protected with metal, wood, or

plastic caps or plugs.

8.3.3 Austenitic stainless-steel valves shall not be exposed to salt water or salt spray. Valves shall be covered, or protected with a coating, and shall not be in contact with porous materials such as raw wood.

8.4

Identification and Labelling

8.4.1 Valves that have passed the required high-pressure double-block-and-bleed or double-isolation-

and-bleed closure test shall be permanently marked or tagged “Bleed-Tested.”

8.4.2 Manufacturer’s standard soft-seated valves shall be permanently marked or tagged with the valve temperature pressure rating at 38 ºC (100 ºF) and at minimum and maximum rated temperature. For valves with a preferred flow direction, this data shall be given for both the preferred and non- preferred directions.

8.4.3 Valves with a preferred flow direction shall have the direction of flow cast on the valve body.

8.4.4 All soft-seated quarter-turn valves of a design that has passed the “fire-tested” requirements of

API STD 607 shall be tagged “Fire-Tested Design”.

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8.4.5 Each valve shall be tagged with a unique number provided as part of the order. The project shall specify appropriate tagging numbers consistent with the valve tagging instructions.

8.4.6 All tags shall be a corrosion-resistant material attached with corrosion resistant wire or cable.

8.5

Documentation

8.5.1 For all sized valves, as a minimum, the following documentation shall be provided as part of the valve order delivery and shall be in accordance with the requirements of API SPEC 6D if there is no other applicable industry standard:

MTRs for body, bonnet/cover(s), and end connector(s)/closure(s)

Valve fire test certificates that represent the actual valves furnished (where required)

Certificate of compliance with NACE MR0175/ISO 15156 for sour services (as applicable)

Cross-sectional drawings that depict details of seat design along with a parts and materials listing

Installation, operation, and maintenance instructions/manuals

Certification of conformance to the industry standard that the valve is specified to meet.

8.5.2 All material certifications shall be in accordance to the EN 10204 Type 3.1 in general and Type 3.2 for Sour services complying with NACE MR 0175/ISO 15156. Material Certificate shall show the chemical composition, mechanical test records, heat treatment records and any other records of supplementary tests specified in purchase order.

8.5.3 Unless otherwise specified Material Certificates to EN 10204 for non-metallic seats shall be 2.2

and non-metallic seals shall be 2.1.

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9 APPENDICES

Appendix 1 Seal Qualification

A.1 Seal Qualification

1. Seal qualification is carried out in two steps:

a) Compatibility Testing: Exposure testing of the elastomer compound to the service

environment

b) Performance Testing of the seal design, after the seal material has passed compatibility

testing

2. A Qualification Test Plan shall be submitted to Company for review and approval. However, qualification does not always require testing if there is valid previous Supplier test data (Engineering Reference Testing) or field experience that is relevant, valid, and acceptable to Company.

3. Company rights and requirements, such as admission to test areas, witnessing of tests, data accessibility, documentation, etc. are outlined in Appendix B Section B.3, for valve testing. These rights and requirements also apply to compatibility and performance testing.

A.1.1 Compatibility and Explosive Decompression Testing

1. Qualification to the environment can be based on past Supplier or Company experience, industry knowledge, or previous testing. If this information is not available or is questionable, compatibility testing can be performed at a Company-approved elastomer laboratory.

2. Two techniques are used for basic compatibility screening of elastomeric materials in liquids, and both start with immersion testing (ASTM D 471 and ISO 1817). The first technique involves testing for changes in material mass and volume as a function of time. This test is generally performed until equilibrium is achieved. The second is generally performed in parallel where changes in elastomer physical properties, such as hardness, modulus, etc., are either tracked intermittently or when the mass and volume changes reach equilibrium. Supplier shall propose compatibility test method (or submit prior test data) for Company approval.

3. Compatibility testing considerations are as follows:

a) Exposure fluids and/or gases and carrier fluid

b) Exposure temperature

c) Exposure pressure

d) Exposure time

4. Any aging or ED testing shall be performed in accordance with NORSOK M-710 or Company- approved equivalent. Exposure time rate of decompression, and number of cycles, will be approved by the Company Elastomer SME.

5. When the Supplier-selected elastomer material is accepted by the Company Elastomer SME, performance testing of the elastomer seal molded from the selected elastomer can be performed, if no previous test records are available for the required duty/environment.

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A.1.2 Performance Testing

1. Acceptance of any pressure-containing assembly is contingent upon successful testing of that final assembly with the seals that are part of that assembly. This testing must be performed at the rated pressure, as a minimum, while at the extremes of the rated temperatures. Thus, a valve rated to 100 bar (1450 psi) at −29°C to 120°C (−20F to 250F) must be pressure tested at −29°C (−20F) and 121°C (250F) to the rated pressure.

2. Performance testing validates only the use of a specific seal configuration and seal compound for a given assembly. Extension of this validation for other assemblies is subject to Company approval.

3. Performance testing should closely approximate the intended use of the seals in the field. If a tool is expected to have pressure reversals with RGD between reversals, a test approximating this service should be devised. Reason and practicality should also be used in designing a test. Refer to Appendix B for an example of a surface valve test to substantiate pressure integrity at the rated temperature range of a valve.

A.1.3 Seal Design

1. The most common types of seal design used in oilfield equipment are interference seals, such as O-rings, T-rings, and U- or V-ring pressure-energized lip seals. The U-ring and V-ring lip seals may have either a spring or an O-ring energizer that must also be considered when there is a chemical compatibility issue. For resistance to very aggressive environments, the preferred materials for both static and dynamic applications are spring-energized thermoplastic seals and a seal stack, assuming long-term performance has been demonstrated by Suppliers.

2. Interference seals will be found in all forms of oilfield equipment, from surface equipment,

such as valves and flow control equipment, to subsea equipment and downhole tools.

3. In surface valves, thermoplastics such as Nylon®, Devlon®, Teflon®, or PEEK are used as

valve seats to seal against a ball, poppet, or flapper (see Table 5.1& Table 5.2).

4. For subsurface packer tools, rubber, such as NBR, HNBR FKM, or TFE/P (Aflas®), is used

for packer elements used to seal against well casing or in open hole conditions.

A.1.4 Spliced O-rings

Single piece O-rings and seals (no joints) shall be the choice for sealing in critical applications. The use of spliced O-rings and seals requires approval by Company Elastomer SME.

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A.2 Quality Assurance Requirements

After qualification, ongoing Quality Assurance and purchasing control must be in place to ensure that the qualified elastomer compound and seal configuration is purchased for use in the field. There must be a clear path between identification of the elastomer compound and configuration tested and the elastomer compound and configuration used in the equipment supplied to Company. If the Equipment Manufacturer has multiple sources for elastomer seals, steps should be taken to ensure that the qualified seal is purchased for use in equipment supplied to Company. The following sections list elastomer and thermoplastic documentation required from Supplier. For convenience, the elastomer documentation requirements are supplied in a matrix form in Table A- 1, with additional guidance on submittals.

A.2.1 Elastomer Properties and Information to be Supplied to Company

1. For all elastomeric seals to be supplied to Company, the following elastomer information shall be presented to Company upon request and with Supplier’s quotation in the form of a Material Data Report (MDR) or Material Data Sheet (MDS): a) Molder (e.g., James Walker, Parker, etc.). b) Compound type (e.g., FKM-Viton®, or Nitrile). c) Compound number or identification (e.g., James Walker’s FR 25/90 or Elast-O-Lion

101).

d) Tensile strength per ASTM D 412. e) Elongation per ASTM D 412. f) Tensile modulus at various elongations per ASTM D 412. g) Hardness per ASTM D 2240. h) Compression set at several temperatures per ASTM D 395. i) Aging properties in air and in various media. Company may also request aging

properties in the service environment.

j) Swelling properties in various media, particularly those to be encountered in the service

environment, and immersion testing per ASTM D 471.

k) Resistance to ED (if appropriate), when elastomers will be exposed to low- and high-

pressure gas systems (e.g., such as topside facilities) per NORSOK M-710.

l) Glass transition temperature for low temperature applications if applicable or requested.

2. At Company’s discretion, Supplier’s information that is less than shown above may be accepted, but Company reserves the right to request additional properties from Supplier if deemed necessary.

A.2.2 Supplier’s Traceability Documentation

1. Supplier shall maintain in its records documentation to provide traceability of each batch of elastomer compound. Elastomer Quality Records or Material Test Reports (MTR) for each batch shall include the following compound identification information: a) Molder (e.g., James Walker, Parker, etc.). b) Compound type (e.g., FKM-Viton, NBR, etc.). c) Compound number or identification (e.g., FR 25/90 or Elast-O-Lion 101). d) Batch number. e) Cure/mold date. f) Shelf-life expiration date. g) Mechanical property data for each batch:

i) Hardness

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ii) Tensile properties iii) Elongation

2. Other information relevant to the Equipment Manufacturer’s specification, such as handling

and installation requirements, shall be supplied to the Company.

A.2.3 Seal Packaging Identification

When shipped from the Molder/Supplier, to assist in traceability, all seals will be appropriately packaged and identified with labels with the following identification information:

1. Molder (e.g., James Walker or Oldrati).

2. Compound type (e.g., FKM-Viton).

3. Compound number or identification (e.g., FR 25/90 or Elast-O-Lion 101).

4. Batch number.

5. Cure/mold date.

6. Shelf-life expiration date.

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Table A- 1 : Elastomer Documentation Requirements

Requirement

Required at Quote

Required on MTR

Comments

S.n o

1 Elastomer Type

2 Elastomer Compound Number

3 Elastomer

Manufacturer

4 Strength

Properties

Y

Y

Y

Y

Y

Y

Elastomer manufacturer to note Revision Level of compound spec.

Identification of Sub suppliers is not required.

Y Acceptable

Range of Values

Y Actual Values for Batch

Per ASTM D 412

5 Elongation

Y Acceptable

Range of Values

6 Hardness

Y Acceptable

Range of Values

Y Actual Values for Batch

Per ASTM D 412

Y Actual Values for Batch

Per ASTM D 412

7 Compression Set at Several Temperatures

8 Swelling

Properties

Y Typical Values

N N/R

Per ASTM D 395

Y Typical Values

N N/R

Per ASTM D 471

9 ED Resistance

Y Typical Values

N N/R

Per NORSOK M-710

10 Glass Transition Temperature

Y Typical Values

N N/R

Gehman test data (ISO 1432) or other standard low temperature test data can be submitted for review.

11 Batch Number

N N/R

12 Cure/Mold Date

N N/R

Y Actual Values for Batch

Y Actual Values for Batch

13 Shelf Life

N N/R

Y

Key: Y = Yes ; N = No ; N/R = Not Required

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Appendix 2 Reason for Elastomer Seal Qualification

B.1 Reasons for Elastomer Seal Qualification

1. The reasons for elastomer seal qualification are as follows:

a) Qualifying elastomer seals prevents seal failure.

b) Cost of seal failure is almost always higher than qualification and/or testing.

c) All elastomers are not the same and will not perform similarly due to variations in the following:

i) Compound chemical formulation

ii) Compound properties

iii)

Elastomer processing

iv) Molders having different compounds and processing techniques

v) Molder quality systems

d) Confidence in whether a seal will work or not work should be based on proven qualification

testing followed by (if available) proven field service use.

e) Temperature affects elastomer seal performance as follows:

i)

Low temperature dependence of elastomer seal performance: As elastomer seal temperature decreases, the elastomer will gradually become stiffer, harder, and more brittle. As the elastomer temperature approaches its glass transition temperature, it is most likely to affect a seal. Finally, at some temperature near the glass transition temperature, the elastomer can no longer initiate a seal.

ii) High temperature dependence of elastomer seal performance: As elastomer seal temperature increases, the elastomer will gradually become softer resulting in the elastomer modulus decrease as a function of temperature. There will come a point at which the elastomer will lose physical integrity due to temperature, applied pressure and the physical configuration of the seal and the seal mating surfaces. The seal will extrude or tear resulting in leakage.

2. Unlike classical engineering design, currently there is no recognized, industry accepted, systematic analytical approach to predicting the seal performance of elastomeric seals based upon measured physical properties of the elastomer. All current seal designs are based on historical success resulting from experience in various materials and configurations. Therefore, a manufacturer cannot guarantee the performance of an elastomer (rubber) seal in particular conditions except by qualification and testing.

B.2 Performance or Type Testing

1. After Supplier and the Company Elastomer SMEs have agreed on an elastomer type and elastomer compound, the chosen compound should be fabricated (molded) into the chosen seal design. In turn, the seals to be qualified should be pressure tested to full rated pressure at the extremes of the rated temperature range.

2. Section B–3 provides a sample test procedure for a bidirectional surface valve. This procedure is a highly reduced version of the API SPEC 6A, Annex F “Performance Verification Procedures” performance test.

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B.3 Surface Valve Sample Test Procedure

B.3.1 Scope

1. This valve High/Low temperature design qualification guideline applies to all valves included in the Purchase Order and is in addition to the standard API STD 598 or API SPEC 6D valve tests for body and seat.

2. Company reserves the right to witness, photograph, digitally record, and to access and

receive any and all data collected in the execution of this guideline.

B.3.2 Purpose

1. This guideline provides valve manufacturers with minimum valve qualification test requirements. Qualification testing is to provide evidence that Company valves remain fully functional and meet the leakage criteria within the Valve Data Sheet (VDS) full pressure/temperature envelope.

2. The Valve Manufacturer shall provide a detailed procedure for the High/Low Temperature Test, and a detailed Test Form to record relevant data, for Company review and approval. Company approval of qualification test procedures is required prior to the commencement of qualification testing. The Valve Manufacturer must give advance notification to Company prior to valve assembly and qualification testing.

3. If the Valve Manufacturer can provide test reports for the same valve design and operating conditions, Company may waive test requirements of this guideline from the Purchase Order. The reported testing must meet the minimum criteria of this guideline.

B.3.3 Test Valve Selection

1. Scaling per API SPEC 6A, Annex F, Section F.1.14 “Scaling” and Section F.1.14.3.2 “Verification by Size,” test valve size shall be representative of the valve being qualified. This valve shall be of the same design, size, pressure, and temperature rating as the valve or valves being qualified. Testing of a different size of valve in the product family is acceptable if the tested size is of one nominal size larger or one nominal size smaller than the qualified valve size.

2. Minimum Material Conditions (MMC): The preferred type of tested valve is a valve manufactured to minimum material conditions. In other words, an MMC test valve would have all seal support surfaces and sealing surfaces manufactured to allow for maximum gap or worst-case conditions with regard to machining tolerances. Any variance from MMC on the part of the Valve Manufacturer must be approved by Company Representative.

B.3.4 General Seal Requirements

The following requirements are intended to ensure that the same seal compounds tested in the test valve are also used in the production valves.

1. All elastomer and nonmetallic seals used in the valve qualification shall be identified by Manufacturer and include as a minimum the elastomer compound number and elastomer batch or lot number. Any exceptions shall be noted in the test procedure and if accepted by the Company Representative will be signed off by the Company Representative.

2. The elastomer compounds tested and qualified shall be molded from the same compound formulation as those to be delivered to Company. It is not necessary to use the same batch and lot numbers. Substitutions of other elastomer compound formulations are not acceptable

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unless these substitutions are tested themselves to the same requirements within this guideline. The Valve Manufacturer must have certifications (test data to verify the design parameters of the material) on all elastomers tested.

B.3.5 Material Inspection

1. Prior to assembly, all metallic and non-metallic valve components shall be collected in a kit for each valve, complete with all associated material certification and receiving inspection reports. Company reserves the right to review all documentation and to witness the dimensional inspection of components prior to assembly.

2. All non-metallic seals shall remain unopened in the original Supplier packaging.

B.3.6 Valve Assembly

1. Company reserves the right to witness the assembly of all valves and to be present when the non-metallic seal packages are opened, and the seals are installed in the appropriate seal glands.

2. If for any reason or at any time a valve has to be disassembled, Company reserves the right

to be present and to witness all work done to the valve, as well as the reassembly.

B.3.7 Test Equipment

1. All pressure equipment shall be capable of pressurizing the valve in accordance with ASME

B16.34, or to the maximum pressure indicated on the VDS if it is less.

2. All cooling and heating equipment shall be capable of heating and cooling the complete valve assembly to the respective minimum and maximum temperatures indicated on the VDS.

3. Test equipment shall include electronic monitoring equipment that records and displays test temperatures and pressures on a real time basis. All test instrumentation shall continuously record pressure and temperature during each test cycle in a permanent (electronic and chart paper) format. The electronic records of pressure and temperature data will be in a delimited format (comma or space delimited) or in such a form that these data can be imported into Microsoft Excel for analysis.

4. All test instrumentation, including leak-sensing equipment, shall be calibrated at calibration levels per ISO 14310, Section 7.4.14 “Calibration Systems.” Company reserves the right to inspect all instrument calibration records prior to testing, and copies of calibration certificates shall be appended to all test records.

B.3.8 Pressure/Temperature Testing

1. Company reserves the right to be present and to witness all pressure test activities.

2. Prior to the qualification test, the valve shall be pressure tested in accordance with API STD

598 or API SPEC 6D as specified in the valve Purchase Order.

3. The qualification test requires a minimum of five pressure cycles at specified temperatures: three ambient, one low, and one high temperature, similar to the API SPEC 6A, Annex F, Section F.1.11 “Pressure and Temperature Cycles,” Figure F.1 “Test Procedure” test format.

4. All tests require the valve to be pressurized in accordance with ASME B16.34, or to the maximum pressure indicated on the VDS if it is less, using 100 percent nitrogen or using a 99 percent nitrogen and 1 percent helium mixture.

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5. The low and high temperature tests will be conducted at the extremes of the valve temperature ratings. The entire valve assembly shall stabilize at the test temperature and pressure before the test hold time begins and shall remain stabilized during the duration of the test hold period, or the test shall be rejected. The test pressure shall be the maximum valve design pressure as stated on the VDS.

6. Pressure (per API SPEC 6A Section F.1.10 “Pressure and Temperature Cycles”) shall be considered stabilized when the change rate is no more than 5 percent of the testing pressure per hour or 34 bar/hour (500 psi/hour), whichever is less. Pressure shall remain within 5 percent of the testing pressure or 34 bar (500 psi), whichever is less, during the hold period.

7. Temperature (per API SPEC 6A Section F.1.10 “Pressure and Temperature Cycles”) shall be considered stabilized when the rate of change is less than 0.5°C (1 F) per minute. The temperature shall remain at or beyond the extreme during the hold period but shall not exceed the extreme by more than 11°C (20°F).

8. Each temperature test cycle requires three pressure tests:

a) Seat A

15-minute hold, 25 scc/min/NPS maximum average leakage

b) Seat B

15-minute hold, 25 scc/min/NPS maximum average leakage

c) Shell

15-minute hold, zero leakage

The valve shall be fully operated between each test, and the operating forces or torques shall be within the Manufacturer’s specifications.

9. All data shall be collected and recorded in accordance with the Valve Manufacturer’s detailed

procedure.

10. If, for any reason, a valve fails any portion of the qualification test, the valve shall be examined in the presence of a Company Representative to determine the cause of failure. The entire qualification test shall be repeated, after approval from Company. A Non- Conformance Report shall be generated in accordance with the Valve Manufacturer’s Quality System.

B.3.9 Test Documentation

1. Prior to testing, Supplier will present to Company all test procedures and schematics of the

test setup for review and subsequent approval by the Company.

2. After Company approval of test procedures and test schematics, Supplier may commence

with testing.

3. All tests are to be documented and all test records provided to Company.

4. In order to minimize confusion and facilitate communication, test documentation supplied to Company shall be in English. Existing internal, manufacturing, and quality documentation shall be translated into English at Company request.

5. Test reports will contain sufficient documentation to explicitly and clearly identify the valve tested and seals, seal configuration(s), seal manufacturer(s), and seal compound(s) tested during the validation test. Additionally, this report should include the ranges of valve designs being qualified by the test performed. Supporting documentation shall be provided such as material certification, inspection support documentation, and raw test data in hard copy format and electronic test data in electronic format.

test equipment calibration certifications,

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Project: Q-21699 - Saipem COMP2 Folder: Material, Painting, Insulation