GUJARAT NARMADA VALLEY FERTILIZERS & CHEMICALS LIMITED 50,000 MTPA PAC PROJECT ANNEXURE 6.4 SECTION 4-07 PROCUREMENT SPECS FOR FORGED VALVES

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1 GUJARAT NARMADA VALLEY FERTILIZERS & HEMIALS LIMITED 50,000 MTPA PA PROJET ANNEXURE 6.4 SETION 4-07 PROUREMENT SPES FOR FORGED VALVES ONTENT 1.0 GENERAL 2.0 DESIGN 3.0 TESTS 4.0 INSPETION 5.0 SHIPMENT 6.0 DOUMENTATION 1

2 GUJARAT NARMADA VALLEY FERTILIZERS & HEMIALS LIMITED 50,000 MTPA PA PROJET ANNEXURE 6.4 SETION 4-07 PROUREMENT SPES FOR FORGED VALVES 1. GENERAL 1.1 Scope This specification covers the general requirements for the valves in design, material, inspection and tests. This specification applies to the following valves: - Gate Valves - Globe Valves - heck Valves - Needle Valves The specific requirements are not included in this specification, which shall refer to "Piping Material Specification" as specified by the ontractor & Approved by Owner For inquiring and ordering purposes, this specification shall be accompanied by Bill of Quantity, which lists size and quantities required against Item ode If any conflict exists between this specification and the related documents described in Section 1.2, this specification shall govern. 1.2 Referenced Documents The following documents shall form an integral part of this specification to the extent specified herein odes and Standards Any codes and standards to be used shall be the latest editions issued before August, a) ANSI/ASME odes and Standards B1.1 Unified Inch Screw Threads B Pipe Threads, General Purpose(Inch) B16.5 Pipe Flanges and Flanged Fittings B16.10 Face-to-Face and End-to-End Dimensions of Ferrous Valves B16.11 Forged Steel Fittings, Socket-Welding and Thread B16.25 Butt Welding Ends B16.34 Valves-Flanged and Butt Welding End B Square and Hex Bolts and Screws Inch Series B Square and Hex Nuts B31.3 hemical Plant and Petroleum Refinery Piping B46.1Surface Texture b) API Standards 598 Valve Inspection and Test 600 Steel Gate Valves, Flanged or Butt Welding Ends 602 ompact Steel Gate Valves c) MSS Publications SP-25 SP-53 SP-54 Standards Marking System for Valves, Fittings, Flanges and Unions Quality Standard for Steel astings and Forgings for Valves, Flanges and Fittings and Other Piping omponents-magnetic Particle Examination Method Quality Standard for Steel astings and Forgings for Valves, 2

3 GUJARAT NARMADA VALLEY FERTILIZERS & HEMIALS LIMITED 50,000 MTPA PA PROJET ANNEXURE 6.4 SETION 4-07 PROUREMENT SPES FOR FORGED VALVES Flanges and Fittings and Other Piping omponents-radiographic Examination Method SP-55 Quality Standard for Steel astings and Forgings for Valves, Flanges and Fittings and Other Piping omponents-visual Method d) ASTM (American Society for Testing and Materials) Standard Specifications The steel valves not specified in paragraph shall conform to the provisions in ANSI B DESIGN 2.1 Body and Bonnet Gate valves shall conform to the requirements of API 600. Globe, check and needle valves shall conform to the requirements of API 600 in so far as applicable. ompact gate valves shall conform to the requirements of class 800 in API 602. ompact globe, check and needle valves shall conform to the requirements of class 800 in API 602 in so far as applicable. 2.2 Body and Bonnet If flange end valves are specified, the end flanges shall be forged integral with or welded to the body, having the same rating as line class. The end flanges attached shall be made by butt welding unless otherwise noted. Their face-to-face dimensions shall conform to ANSI B End flange facing shall be finished as follows: - For compressed asbestos Serrated finish with roughness and TFE sheet of 125 to 500 AARH - For spiral wound: Smooth finish with roughness of 125 to 250 AARH - For ring joint groove: Roughness of 63 AARH Butt welding ends shall depend on the connected pipe wall thickness and outside diameter specified on purchase order document onnection ends of valves shall be as follows: - Threaded end(npt) : ANSI B Socket welding end : ANSI B Butt welding end : ANSI B The body to bonnet joint facing shall be designed to confine the specified gasket against blowout An extension bonnet, when required, shall be integral with the bonnet but a tube extension may be welded to the bonnet with full penetration welding The thread of bonnet/cover bolting, gland bolting, and stem may be in accordance with manufacturer's standard. 3

4 GUJARAT NARMADA VALLEY FERTILIZERS & HEMIALS LIMITED 50,000 MTPA PA PROJET ANNEXURE 6.4 SETION 4-07 PROUREMENT SPES FOR FORGED VALVES The port diameter and seat bore shall be reduced bore unless otherwise noted. 2.3 Disc and Seats The discs of valves shall be of - Wedge gate type for gate - Disc type for globe - Piston type for check The discs shall be of a solid(one-piece) type with integral of weld deposited seating surfaces The body seats shall be of either: - A separate ring welded into the body - A hard faced deposit on the body(direct deposition of 13% chromium seat material on to the body is not acceptable.) - Integral with the body which are specified "Integral" on the "Piping Material lassification" If the seat surfaces with a hard faced deposit is specified, the integral seat is acceptable instead of the renewable seat. The seat surfaces with no hard faced deposit shall be the renewable seat except austenitic stainless steel valves If a combination trim, e.g. a hard faced deposit and 13r is specified, the former shall be used for the body seat surface and the latter for the disc seat. 2.4 Material Except as modified herein, material specifications as well as inspections and tests shall be strictly in accordance with the standards referred to this specification Hand wheels shall not be made of gray iron or non-metallic materials Valve stem packing and body/bonnet gaskets shall be equivalent in quality and performance to those specified on "Piping Material lassification" For material of stainless steel valves, type 316 may substitute for type 304 stainless steel IBR VALVES For SW/BW end carbon steel valves under the chemical composition shall conform to the following: arbon (Max.) : 0.25% Others (S, P, Mn) : As per IBR regulations. The above composition is not valid for non-ibr valves. 3. TEST 3.1 General Shop inspection and tests shall be carried out to API 598 and related MSS Standards. 4

5 GUJARAT NARMADA VALLEY FERTILIZERS & HEMIALS LIMITED 50,000 MTPA PA PROJET ANNEXURE 6.4 SETION 4-07 PROUREMENT SPES FOR FORGED VALVES 3.2 Non-Destructive Examination (NDT) NDT for valve body and bonnet shall be carried to the provisions of ANSI B NDT requirements, which depend on material and line pressure rating, shall refer to 5

6 GUJARAT NARMADA VALLEY FERTILIZERS & HEMIALS LIMITED 50,000 MTPA PA PROJET ANNEXURE 6.4 SETION 4-07 PROUREMENT SPES FOR FORGED VALVES Table The welds of body-to-bonnet and body-to-end flange shall be subjected to 100% NOT; both radiographic and magnetic or liquid penetrant examinations Beveled ends on each butt welding end valve shall be subjected 100% magnetic particle or liquid penetrant examination. 3.3 Pressure Tests Each valve shall be pressure tested in accordance with API High pressure closure test shall be required for gate and globe valves Water for pressure tests on austenitic stainless steel valves and those having internals of austenitic stainless steel shall not contain chlorides more than 50 ppm in weight. 4.0 INSPETION 4.1 Inspection authority means the inspection agencies approved by the Owner. Approved inspection agencies are: M/s. Lloyds, TUV & BVIS Inspection Agency are approved for overseas Vendors for Non-IBR items. M/s. LRIS, RW - TUV & BVIS Inspection Agency are approved for Indigenous vendors for Non-IBR items. For IBR Items, Please refer to Annexure Valves meant for steam service are marked IBR in piping bill of materials. These valves shall be tested in accordance with the requirements of IBR and certified in form III by authorized inspection agency for the steam conditions as per data sheets. 4.3 The inspecting authority shall be provided free access at all reasonable time to those parts of supplier s work engaged in production and testing of materials ordered. 4.4 The inspecting authority shall have the right to select random samples for check test and reject materials, if samples furnished as above and tested as per the specifications fail to meet the requirement specified. 4.5 Quality assurance plan shall be approved by concerned Owner s inspection department OR Inspection Agency before starting of assembly & testing of valves. 4.6 All valves shall be inspected during various stages of manufacturing starting from identification of raw materials to completion. Valves shall be considered acceptable for dispatch only after final certificate of acceptance is issued by the inspector. The various stages of inspection of valves include inspection of valve casting, forging, spindle and trim materials received from sub-supplier by co-relating test certificates and check analysis wherever required. Parts assembled in valves such as bonnet, wedge, seats, gland packing etc. shall be inspected prior to assembly of valves for workmanship and long life. After the assembly of valves, the hydro test with water or air test for body & seat shall be carried out for each valve as per specified standard and test pressures. Finally all valves are to be cleaned, dried and painted only after final acceptance 6

7 GUJARAT NARMADA VALLEY FERTILIZERS & HEMIALS LIMITED 50,000 MTPA PA PROJET ANNEXURE 6.4 SETION 4-07 PROUREMENT SPES FOR FORGED VALVES certificate is issued by inspector. The vendors who are having ISO 9001 certification shall not be relaxed for any of 7

8 GUJARAT NARMADA VALLEY FERTILIZERS & HEMIALS LIMITED 50,000 MTPA PA PROJET ANNEXURE 6.4 SETION 4-07 PROUREMENT SPES FOR FORGED VALVES the stages of inspection mentioned above. They may give 15 days notice to the concerned inspector for every stage of inspection so that their production schedule is not affected. 4.7 Testing performed in the presence of the purchaser s representatives shall not relieve the supplier of their own responsibilities and guarantees and any other contractual obligations SHIPMENT 5.1 Marking and Nameplate All valves shall be marked in accordance with ANSI B Nameplates shall not be attached on the pressure parts by means of tapping, drilling or others reducing body wall thickness. 5.2 Preparation for Shipment Exterior surfaces of the shell shall be painted as follows: - Painting for carbon steel, Al-killed carbon steel and low alloy steel valves. - No painting for austenitic stainless steel Threaded or socket-welding ends of valves shall be protected with plastic, metal, or wood plugs. End flanges shall be fully blanked with plastic, metal or wood covers to protect the gasket surfaces or welding ends and valve trim during shipment and storage. End connections of valves shall be coated with rust preventive which can be removed easy at site. Gate or globe vales shall be shipped with the disc closed. All IBR valves shall be painted red in body bonnet / body cover joint. Table Non-Destructive Examination Requirements for Body and Bonnet asting valve Forged valve MATERIAL RT MT OR PT MT OR PT Al Killed arbon steel arbon steel 0.5 Mo Steel 0.5 r 0.5 Mo 1 r 0.5 Mo 1.25 r 0.5 Mo D B D B E AUSTENITI SS Low Temperature Service A A B 8

9 GUJARAT NARMADA VALLEY FERTILIZERS & HEMIALS LIMITED 50,000 MTPA PA PROJET ANNEXURE 6.4 SETION 4-07 PROUREMENT SPES FOR FORGED VALVES Normal Service High Temperature Service D D E 9

10 GUJARAT NARMADA VALLEY FERTILIZERS & HEMIALS LIMITED 50,000 MTPA PA PROJET ANNEXURE 6.4 SETION 4-07 PROUREMENT SPES FOR FORGED VALVES Notes: NDT shall be performed with following classification: A: For Line lass 150 # and over B: For Line lass 300 # and over : For Line lass 600 # and over D: For Line lass 900 # and over E: For Line lass 1500 # and over Abbreviation: NDT: Non Destructive Examination RT: Radiographic Examination. MT: Magnetic Particle Examination PT: Liquid Penetrant Examination. 6.0 DOUMENTATION 6.1 Valves coming under the purview of IBR (Indian Boiler Regulation) shall each be individually accompanied by IBR certificate original in form III- duly approved by IBR authority /local authority empowered by the central Boiler Board of India. Photocopy of original certificates duly attested by the local boiler inspector where the supplier is located is the minimum requirement for acceptance. 6.2 The manufacturer shall submit the following with the offer: omplete descriptive and illustrative catalogue/literature. Detailed cross section drawing with pacts / material lists, weight etc. the ball valves, plug valves, butterfly valves, diaphragm valves and valves to manufacturer s standard. Drawings for valves with accessories like gear operator, hydraulic /pneumatic operator, motor, extension bound; extended stems with stands, bypass etc. giving major dimensions. One copy of the valve specification sheet signed as Accepted by the manufacturer with all deviations marked clearly. If the valve is regretted or has no deviations the manufacturer shall write clearly on valve specification sheet as REGRET or NO DEVIATION For subject notes if there is any deviation, the same shall be listed clause wise. Even clauses which are acceptable shall be categorically confirmed as accepted. On failure to submit documents as specified in from points (i) to (vi) the offer is likely to be rejected. 6.3 Six copies of sectional assembly drawings after receipt of L.o.i. incorporating manufacturing, testing Std, valve dimensions, part list including material specification, Tag. No., Purchase Order No. etc. for purchaser s approval before starting manufacturing. The valve shall be manufactured as per delivery schedule on the basis of drawings approved by the purchaser within 4 weeks 6.4 The manufacturer shall submit the following drawings and documents in 8 copies each along with the supply of material. In addition 4 copies shall be sent to onsultant 10

11 GUJARAT NARMADA VALLEY FERTILIZERS & HEMIALS LIMITED 50,000 MTPA PA PROJET ANNEXURE 6.4 SETION 4-07 PROUREMENT SPES FOR FORGED VALVES Material test certificates for body and trim materials. (In this, supplier must indicate clearly chemical composition and physical properties). 11

12 GUJARAT NARMADA VALLEY FERTILIZERS & HEMIALS LIMITED 50,000 MTPA PA PROJET ANNEXURE 6.4 SETION 4-07 PROUREMENT SPES FOR FORGED VALVES Hydraulic test certificate. Manufacturer s guarantee certificate. Approved sectional drawings of the valves showing complete dimensions with part number and description for easy identification along with the material of construction etc. I.B.R certificate in Form III duly signed by the inspecting authorities for valves meant for steam service. Inspection and test certificates for Non-IBR items signed by inspecting authority. 6.5 Manufacturer is required to keep proper records of all the certificates such as foundries/forged shop certificates and the check analysis carried out for raw materials. For Acid service having higher temp than 95 Deg. ( Plug Valves to be used & IG Testing with TPI to be carried out. 12

4.1 Type of the valve and materials of construction of body and trim shall be as specified in valve Data sheet.

4.1 Type of the valve and materials of construction of body and trim shall be as specified in valve Data sheet. SHEET 1 OF 5 1.0 GENERAL & SCOPE 1.1 This specification covers the design, material, construction features, manufacture, inspection & testing, Painting and packing requirements of Spring Loaded Bypass