Petroleum Development Oman L.L.C.Document title: Document ID SP-2154 Document Type Valves Technical Specification Security Unrestricted Discipline Mechanical – Static/Piping Owner Abdulnabi Al-Balushi, UEP/1S Issue Date 15-July 2013 Version 0 Keywords: This document is the property of Petroleum Development Oman, LLC. Neither the whole nor any part of this document may be disclosed to others or reproduced, stored in a retrieval system, or transmitted in any form by any means (electronic, mechanical, reprographic recording or otherwise) without prior written consent of the owner. Petroleum Development Oman LLC This page was intentionally left blank Revision: 0 Effective: July-13 Page 2 Valves Technical Specification 15/07/13 The controlled version of this CMF Document resides online in Livelink®. . Printed copies are UNCONTROLLED. . 0) Design. 0 Date 15 July 2013 Author Mahesh Manjakuppam Srinivasan Scope / Remarks First Issue iii Related Business Processes Code EP 64 Business Process (EPBM 4. Details of all revisions prior to these are held on file by the issuing department. Printed copies are UNCONTROLLED.Petroleum Development Oman LLC Revision: 0 Effective: July-13 ii Revision History The following is a brief summary of the 4 most recent revisions to this document. Modify or Abandon Facilities iv Related Corporate Management Frame Work (CMF) Documents The related CMF Documents can be retrieved from the Corporate Business Control Documentation Register CMF. Version No. Construct. . Page 4 Valves Technical Specification 15/07/13 The controlled version of this CMF Document resides online in Livelink®. ................................................................................................................................................................ 6 General requirements: .........1 4............................................................................................................................. 11 4..................... 10 3.................................................................................................................................................................................................................. 7 Seat and Sealing ............................................ 7 2............................................................................... 10 4 Inspection and Testing .. 6 1......................................................................................... 11 TAT requirements: .......7 2...... ..........................................3 2................................................... 6 Exceptions ........................................................ 7 Valve Operator ..................................................2 2............Glossary of Definitions........................................................................................................................... 11 5 6 Appendix A ..1 2.................................2 1.......... 3 Revision History ......................Petroleum Development Oman LLC Revision: 0 Effective: July-13 TABLE OF CONTENTS i ii iii iv 1 Document Authorisation ..... 12 Appendix B – Typical Lip seal Arrangements .... 9 3 Special Services ......................................... 8 Valve lifting and supporting provision .................................................................................................................... 6 Reference Documents ..................................................8 Design and Construction ........................................................................ Terms and Abbreviations ..2 Additional Inspection / Testing Requirements: ........................ 9 Vent / Drain Connection ..............................................................................................1 1.................................................................3 1.................................................................................................................................................................... 4 Related Business Processes ..................................6 2............................................................ 15 8 9 Appendix D – Typical arrangements of Vent and Drain with threaded plug: ........................ Printed copies are UNCONTROLLED................................................... 6 Changes to the Specification ... 9 Weld overlay................ 17 Page 5 Valves Technical Specification 15/07/13 The controlled version of this CMF Document resides online in Livelink®............................. 13 7 Appendix C – Typical Arrangements of CRA sleeve weld detail in drain / vent port of Weld overlay valves: ..............4 2................................................................................................................................................................................................................................................................ 4 Related Corporate Management Frame Work (CMF) Documents ................................. 4 Introduction .......................................... 16 Appendix E User Feedback Page ................................1 ESD/IPF/HIPPS Ball Valves ... 9 Painting and Coating .....5 2............................................................................................ 9 Sub Contracting ......................................................................................................4 2 Purpose ........................................................................................................................ Send the copy with your comments and personal details to DCS after discussion with (CFDH –Static).13-Gen SPE77/313 SPE77/312 SPE77/302 SP1246 SP1173 Specification for pipeline valve Petroleum and Natural Gas industries . CFDH Mechanical (Static). Threaded and welding end Face to Face and End to End Dimensions of valves Human Factors Engineering-Valves. vendor shall seek approval from the Company. Any work completed with unauthorised modifications may be rejected by the Company.00. The purpose of this specification is to upgrade the valve integrity in terms of reliability and safety.60. who owns this specification.34 ASME B16. write your comments on a copy of the User Comments Form.Petroleum Development Oman LLC Revision: 0 Effective: July-13 1 Introduction 1.1 Purpose This specification shall apply to on plot valves (MESC and Non-MESC categories) in addition to the applicable International codes.3 Exceptions Any proposed exceptions or variations to this specification shall be submitted to the Company or its representative for approval prior to manufacture. . Printed copies are UNCONTROLLED.4 Reference Documents API 6D ISO 14313 API 6A ASME B16. 1.2 Changes to the Specification This specification shall not be changed without approval from the Custodian. In case of any conflict between the requisition/datasheet and this specification. 1. If you think any part of this specification is not correct.Pipeline transportation system Petroleum and Natural Gas industries-Pipeline valves Specification for Wellhead Equipment Valves – Flanged. 1.10 DEP 30. The form is included as the last page of this specification. MESC specification. Any subsequent re-work shall be in accordance with this specification and shall be to the Manufacturer’s/Supplier’s account. SHELL SPE and technical requisition. Valves with CRA Cladding Fugitive Emission Production Testing Valves-General requirements Specification for Painting and Coating of Oil and Gas Production Facilities Welding of Metals Page 6 Valves Technical Specification 15/07/13 The controlled version of this CMF Document resides online in Livelink®. . it shall be of Lip seal type with Eligiloy 718 spring material. for higher temperature Chromium carbide shall be used. No “O” ring is allowed in the Body /bonnet joint Page 7 Valves Technical Specification 15/07/13 The controlled version of this CMF Document resides online in Livelink®.1 Design and Construction Vendor shall have performed required design calculations for all the valves for which they are approved in the PDO PGSC list.Tensile bond strength > 10. If vendor is unable to carry out weld overlay on the seal pocket areas in the smaller size of valve. Hardness 1050HV. 2. Printed copies are UNCONTROLLED. The cast body of valve shall not have any sharp contour which may see crack. Ball valve Seat ring shall have primary lip seal with a fire safe graphite ring. The body/bonnet joint shall have primary static seal or gasket suitable for the designated pressure class and secondary static seal which is of fire safe gasket/seal. 200 DegC. As an alternative to top entry flanged end ball valve vendor can opt for the two (2) piece valve design if vendor has got good past record for such design.Min. For CS ball valve with trim material of DSS or SDSS or Alloy 825 construction. Chevron pack may be acceptable for stem sealing.000 psi . the seal pocket of static/dynamic lip seal or chevron seal shall be with Alloy 625 weld overlay. If the seal material is specified as elstomeric materials it shall be AED (Anti Explosive decompression) type. Refer Annexure-B for the typical arrangement of lip seal arrangement in the ball valve. The Valve rated API 10000# and above shall be metal seated and zero seat leakage across the valve as per API 6A. the valve body/bonnet shall be supplied with the same material of trim.1 certificates for the type seal proposed in the valve and if Company / buyer requests at any time during execution of job shall provide the same for information/reference. The detailed calculation report should be made available if required by company or buyer at any time of execution of job. FEM analysis shall be performed for all the valve categorised to API 6A rating and materials not listed in the ASME B 16. minimum 3 mm corrosion allowance shall be considered in the design unless other wise specified in the requisition.Thickness of minimum 400 microns after grinding and polishing. The temperature limit for the tungsten carbide is max. . The requirements of hard face coating of tungsten carbide (TC) or chromium carbide shall be: . For carbon steel valve. Vendor shall have the material specification and EN10204 2. The hard facing of metal seated high pressure ball valves (ASME 1500 # and higher) shall be with Tungsten carbide or Chromium carbide. shrinkage and blow hole as the molten materials may not flow smoothly to the sharp corner of the valve during casting.34.2 Seat and Sealing If the seal material specified in the requisition as thermoplastic.Petroleum Development Oman LLC Revision: 0 Effective: July-13 2 General requirements: 2. and dust and weather proof to IP 55. Table 1. totally enclosed. self-locking type... Valve torques can vary for different manufacturers and shall be checked to ensure appropriate selection of gear operators based on the maximum and sustained force requirements provided in this specification. Gear Operator shall be provided for manual valves in accordance with the following table: ASME Class 150 300 600 900 1500 =>2500 Valve Type Gate DN 350 (NPS 14) and larger DN 300 (NPS 12) and larger DN 150 (NPS 6) and larger DN 100 (NPS 4) and larger DN 100 (NPS 4) and larger DN 80 (NPS 3) and larger Globe / Plug DN 250 (NPS 10) and larger DN 200 (NPS 8) and larger DN 200 (NPS 8) and larger DN 150 (NPS 6) and larger DN 80 (NPS 3) and larger DN 80 (NPS 3) and larger Ball DN 150 (NPS 6) and larger DN 100 (NPS 4) and larger DN 100 (NPS 4) and larger DN 80 (NPS 3) and larger DN 80 (NPS 3) and larger DN 80 (NPS 3) and larger Butterfly DN 200 (NPS 8) and larger DN 200 (NPS 8) and larger NOTES: 1. [Where specified. Manufacturers can provide gear operators for lesser size also as per their standards. the gear enclosure shall be water proof/splash proof to IP 65. For hand wheels or levers between 50 mm (2 in) and 125 mm (5 in) in diameter or length(i. intended for one-handed operation) the maximum force shall not exceed 66 N (15 lbf). wrench or hand wheel. The maximum dimension of hand wheel and lever shall be according to requirements of ISO 14313 except the maximum hand wheel diameter is limited to 800mm and the maximum lever length is limited to 450mm. electric or pneumatic) or mobile operators upon approved by company. as measured on the rim of the hand wheel or the end of the lever or wrench. grease-filled.as measured on the rim of the hand wheel or end of lever or wrench.. The direction of operation shall be clockwise for closing the valves. 2.5 times the maximum required operations torque of the valve.] The gear operator shall be adjustable at 45 – degree increments in the field Page 8 Valves Technical Specification 15/07/13 The controlled version of this CMF Document resides online in Livelink®. The maximum force required to initially crack open a valve at maximum differential pressure with a hand wheel or lever of more than 125 mm (5 in) in diameter or length shall not exceed 445 N (100 lbf). Printed copies are UNCONTROLLED.e.0 Valve that requires more than 100 turns to go from fully open to fully closed should be equipped with actuators (hydraulic.3 Valve Operator Revision: 0 Effective: July-13 Manually operated valves shall be operated by a lever.Petroleum Development Oman LLC 2.. suitable for outdoor installation. . The gear box output torque rating shall be at least 1. Gear operator shall be heavy duty. 5 Weld overlay For top entry ball valves. The minimum size of flanged vent and drain port shall be one (1) inch. 2. The valve bolting (B7 / B7M) shall be with ENP + PTFE top coated for the design temperature less than 200 Deg C.4 Valve lifting and supporting provision Revision: 0 Effective: July-13 Valves of sizes 8”NPS (200NB) and above or 250Kg and heavier shall be equipped with lifting lugs. which must be obtained at the time of bidding stage. 2.Petroleum Development Oman LLC 2.6 Vent / Drain Connection The plug material shall be same as the trim material. If any works are outsourced after company approval. the manufacturer shall maintain full QA/QC control over sub contracting activities. Any deviation to this. the plug shall be extended to full length of port so that no accumulation of solid particles / debris is entrapped in the drain port. it shall be weld overlay and minimum finished thickness of welded-on hard facing material shall be 3. Page 9 Valves Technical Specification 15/07/13 The controlled version of this CMF Document resides online in Livelink®. 2. The sub contractor of Weld overlay works shall be approved by company prior to commence any weld over lay works. Refer Annexure-D No seal welding should be performed on the plug after shop or field Hydro testing. 2. Printed copies are UNCONTROLLED. The 6 inch and smaller valve size shall be of solid CRA material. Lifting lugs position shall allow for safe handling of valve with Gear box or actuator. Valve ends shall be covered with close fitting protectors made of plastic caps to protect the machined parts and prevent ingress of dirt and moisture. The flanged connections shall be butt welded to the body or pad type flanged. The vent /drain plug shall have threaded cover cap as shown in the sketch. unless otherwise specified. The Alloy 625 /825 / Alloy28 body does not require any coating / painting. requires a prior approval from the company. If the drain port is at the bottom most portion of the body. Tapped holes and eye bolts shall not be used for lifting...0 mm.7 Painting and Coating The painting and coating of valve body shall be as per SP-1246. The support height shall be as minimum as possible. Valve shall have saddle or leg bottom support for the valve weighing more than 750kg with gear box/actuator and the supports should be designed to take care of the vertical and lateral loads of valves with operators. the internal CRA weld overlay in the body /bonnet is applicable only for size 8 inch and above.8 Sub Contracting All valves are deemed to be machined. No socket welded pipe with flange connection is permitted. assembled and tested at the company approved premises. The weld overlay of valve body vent /drain port shall be similar to the arrangement shown in the Annexure-C. If stellite is specified as hard facing. . . The SP (single Piston) and DP (Double Piston) shall marked permanently on the respective seat side and flow arrow shall be embedded on the body.1 ESD/IPF/HIPPS Ball Valves The valve shall be of trunnion type with metal seat arrangement and minimum size of 2 inch.) with a fire safe graphite ring. The upstream seat shall be with single piston effect and down stream seat with double piston effect. However. the valve shall be suitable for bi-directional isolation.built check valves. No seat sealant injection shall be provided for these valves. The Seat ring shall have primary lip seals (2 nos.Petroleum Development Oman LLC Revision: 0 Effective: July-13 3 Special Services 3. The grease fitting shall be provided between primary and secondary seal on the stem side with two in. The stem side shall have minimum two (2) primary lip seals or U or V shaped packing with fire safe secondary seals. The Grease thread fitting shall be anti blow out plug type and with two (seals). Page 10 Valves Technical Specification 15/07/13 The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED. The material of grease fitting shall be same of valve trim material. . All the valves irrespective of materials and service shall be assigned IC-IV for the class above 600# and IC-III for the class 600# and below or as per inspection criteria of SPE 77/302. If the waiver to TAT is required. In the event of failure. The final inspection and testing including visual inspections prior to packing shall be in accordance with ISO 10474 3.2 material certificates for TPI witness prior to assemble the valves. whichever is stringent. However..2. 2% of valve from each category shall be tested as per B11/B12 of ISO 14313 in case the valves are identified with single and double piston effect combination or both seats are with double piston effect.2 TAT requirements: The TAT as per SPE 77/300A is mandatory which shall be witnessed by PDO or PDO approved TPI in case the valves were not already qualified by SHELL with TAT. 4. Inspection /testing of Painting (Visual/thickness/ adhesive).Petroleum Development Oman LLC Revision: 0 Effective: July-13 4 Inspection and Testing 4. Visual inspections(rough / machined ) WPS /PQR for the weld overlay Required NDEs for the valve and weld overlay. The ITP shall include minimum the following activities: Materials inspections/ testing( body/bonnets/closure members/stem/bolts/nuts/seals) Soft seat material certificates. vendor shall fully comply with the following requirements in addition to MESC.1C certificate or EN10204 3. The soft seal material (Lip seals) material shall be from Saint-Gobain and provide 2.1 of this specification. All valves shall undergo production FE (Fugitive Emission) testing. the valve shall be repaired and retested and another two (2) valves from same category to be selected in random for 30 minutes seat test. All required testing on assembled valves including valve stem torque tests. cavity relief tests. . The API 6A rated valves used for gas service shall be minimum comply with PSL3G and PR2 requirements. Test and inspection of hard facing including sample bond /hardness test. - Page 11 Valves Technical Specification 15/07/13 The controlled version of this CMF Document resides online in Livelink®. All but end valves shall be considered as IC-IV of SPE 77/302. 2% of valve from each category of ordered lot shall be tested with minimum test duration of 1 hour for high pressure shell test: The minimum duration of high pressure seat leak test shall be 5 minutes for all size of valves and one (1) valve from each category shall undergo 30 minutes seat test.1 Additional Inspection / Testing Requirements: Vendor shall not commence the manufacturing of valves unless the ITP is approved by company or buyer. The duration of shell test shall be as per ISO 14313. Printed copies are UNCONTROLLED. TPI shall be involved in all inspection / testing which shall be at vendor cost and vendor shall get company approved on TPI. Tagging and marking Visual inspection prior to packing(internal/external/ fittings on the valve body) Preservation and Packing. SPE 77/302 and section 4. The person within the Company responsible for the discipline to which the standard belongs The party which manufactures or supplies equipment and services to perform the duties specified by the Company. Indicates a recommendation.2 Abbreviations ASME BCD CFDH DCS NDE IPF HIPPS ENP ESD MPI RED American Society of Mechanical Engineers Business Control Document Corporate Functional Discipline Head Document Control Section Non Destructive Examinations Instrument Protective function High Integrity Pressure protective system Electroless Nickel Plating Emergency Shut Down Magnetic Particle Inspection Requisition for Engineering Documents Page 12 Valves Technical Specification 15/07/13 The controlled version of this CMF Document resides online in Livelink®. A design subjected successfully to fire testing A design that by the nature of its features and materials is capable of passing a fire test Buyer Corporate Functional Discipline Head Manufacturer/Supplier User shall should may Fire tested design Fire safe design A. The Company may also include an agent or consultant authorised to act for and on behalf of the Company. Indicates a possible course of action.Petroleum Development Oman LLC Revision: 0 Effective: July-13 5 Appendix A Abbreviations A. EPC/EMC/ODC contractors. .1 Glossary of Definitions. The Company Manufacturer/Supplier or Consultant that uses this document. Printed copies are UNCONTROLLED. Terms and Terms and Definitions Companyr Petroleum Development Oman LLC. Indicates a requirement. Petroleum Development Oman LLC Revision: 0 Effective: July-13 6 Appendix B – Typical Lip seal Arrangements Typical Ball Valve Body/Bonnet arrangement with Lip seal Typical Stem side seal Arrangement with Lip seals Page 13 Valves Technical Specification 15/07/13 The controlled version of this CMF Document resides online in Livelink®. . Printed copies are UNCONTROLLED. Vendor should provide as per their approved standards meeting all the required specifications. 2. .Petroleum Development Oman LLC Revision: 0 Effective: July-13 Typical Arrangement of Lip seal on the ball valve seat ring Note : 1. the seal pocket shall be weld overlay as per section 2.2 Page 14 Valves Technical Specification 15/07/13 The controlled version of this CMF Document resides online in Livelink®.The arrangement shown in the above sketch is just representative only. The Lip seals provided on the CS body / bonnet. Printed copies are UNCONTROLLED. Petroleum Development Oman LLC Revision: 0 Effective: July-13 7 Appendix C – Typical Arrangements of CRA sleeve weld detail in drain / vent port of Weld overlay valves: Note 1: The arrangement shown in the above sketch is just representative only. 4: The sleeve should be cold fitted. . 2: The sleeve shall be with Anti blow out arrangement.Drilling of port shall be done after completion of internal body weld overlay. Page 15 Valves Technical Specification 15/07/13 The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED. 3:. .Petroleum Development Oman LLC Revision: 0 Effective: July-13 8 Appendix D – Typical arrangements of Vent and Drain with threaded plug: Page 16 Valves Technical Specification 15/07/13 The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED. Petroleum Development Oman LLC Revision: 0 Effective: July-13 9 Appendix E User Feedback Page SP-2154 – VALVES TECHNICAL SPECIFICATION USER FEEDBACK FORM Any user who identifies an inaccuracy.Mahesh Manjakuppam Srinivasan Custodian of Document Date: Page 17 Valves Technical Specification 15/07/13 The controlled version of this CMF Document resides online in Livelink®. The user is requested to return this page fully completed. . Printed copies are UNCONTROLLED. Name: Ref ID Date: Page Ref: Brief Description of Change Required and Reasons To: UEP/10S . indicating precisely the amendment(s) recommended. error or ambiguity is requested to notify the custodian so that appropriate action can be taken.