STANDARD SPECIFICATION STANDARD SPECIFICATION No. FOR ON-OFF VALVES 6-52-0037 Rev. 0 Page 1 of22, atate eat faa ase fate STANDARD SPECIFICATION FOR ON-OFF VALVES 0 15.05.07 Issued as Standard Specification sh Tom te ve ‘Slandards Standards Committee Bureau _Convenor_ Chairman, ‘Approved by bate Purpose Propared Checked Format No, 8-00-0001-F1 Rev. 0 (Copyright EI ~ Al nghts reservedSGifetzTeT ae ENGINEERS STANDARD SPECIFICATION “T*NDARD SPECIFICATION No. eee @NSAtRiED a fetsics “> NDIA UMITEL FOR ON-OFF VALVES 6-52-0037 Rev. 0 Page 2 of 22 Abbreviations: AARH Arithmetic Average Root Height CMRI Central Mining Research Institute DD Device Description ERTL Electronics Regional Testing Laboratory HART Highway Addressable Remote Transducer MVT Manual Valve Testing NACE ‘National Association of Corrosion Engineers NPT National Pipe Thread NPS ‘Nominal Pipe Size OSHA Occupational Safety and Health Authority PID Proportional, Integral and Derivative PFD Probability of Failure on Demand PST Partial Stroke Testing PIFE Poly Tetra Fluoro Ethylene ss Stainless Steel TSO Tight Shutoff Instrumentation Standards Committee Convener: H.C. Jain Members: T.G, Mohan RK. Agarwal K.V. Chandramouli R. Priyamvada SKaul Format No, €-00-0007-F1 Rev. 0 ‘Copyright EIL— A ights reservedSTANDARD SPECIFICATION No ENGINEERS STANDARD SPECIFICATION eae SAR FOR ON-OFF VALVES 6-52-0037 Rev. 0 See tte tnenines Page 3.01 22 CONTENTS 10 GENERAL 20 DESIGN AND CONSTRUCTION 3.0 NAME PLATE 4.0 INSPECTION AND TESTING 5.0 SHIPPING 6.0 REJECTION ANNEXURES: ANNEXURE ~ 1 : STUD - BOLTS AND NUTS MATERIAL REQUIREMENT EXURE ~ 2: GASKET MATERIAL REQUIREMENT Format No. €-00-0001-F1 Rev.0 Copyright EI — Alvights reservedSPECIFICATION No. SSA ZRE ENGINEERS STANDARD SPECIFICATION STNDARD tee SNA FOR ON-OFF VALVES eee 0 age 1.0 GENERAL 11 Scope LL.1 This specification, together with the data sheets attached herewith describes the requirement for the design, materials, nameplate marking, inspection, testing and shipping of on-off valves, 1.1.2 The related standards referred to herein and mentioned below shall be of the latest editions prior to the date of the purchaser's enquiry: ANSVASME — American National Standard Institute/American Society of Mechanical Engineer. B 1.20.1 Pipe Threads General Purpose (Inch) B165 Pipe Flanges and Flanged Fittings NPS: through NPS24 B 16.10 Face to face dimension and grooves B 16.20 Metallic Gaskets for Pipe Flanges,Ring Joint, Spiral wound and Jacketed. B 16.34 Valves flanged, Threaded and Welding End. B1647 Large diameter Stee! Flanges ANSI FCI 70-2 Leakage class classification API6D Specifications for Pipelines valves end closures, Connectors and Swivels API6FA Specification for Fire Test of Valves API S98 Valve Inspection & Tests API607-4 _ Fire test for soft seated valves. API 608 Metal Ball Valves — Flanged, Threaded and welding end API609 Lug and wafer type, Butterfly valves. AWWA American Water Works Association - Steel Pipe Flanges For Water Works C207CL.D Services BS 6364 Valves for cryogenic service BS 6755 Part 2 Testing of Valves ~ Specification For Fire type — testing requirements EN 10204 Inspection Documents for Metallic Products. EN 61056-1 Specification for performance, design and construction of valve, regulated sealed type. Indian Boiler Regulation. 0079 Electrical Apparatus for Explosive Gas Atmosphere. TEC-60529 Degree of Protection Provided by Enclosures. IEC-60534-3-2 Face to face dimension of flangeless valves. IEC-60534-4 Inspection & Routine Testing IEC-61508 Functional Safety of Elecirical/Electronic/Programmable Electronic Safety related system. Format No, 6.00-0007-F1 Rev. 0 ‘Copyright EIL~ AlTighis reserved‘STANDARD SPECIFICATION No. BLOM “emma "Ney ee a Page 5 of 22 IEC-61511 Functional Safety instrumented system for the process industry sector 1S-13947 Degree of Protection provided by Enclosures for low voltage switchgear and control gear. 18-2148 Electrical Apparatus for Explosive Gas Atmospheres-Flame proof Enclosures ‘d’. ISA Instrumentation, Systems and Automation Society ANSV/ISA 75.01.01 Flow equation for sizing control valves. 75.02 Control valve capacity test procedure. TR75.04 Control Valve positioner stability 75.05.01 Control Valve terminology. 75.08.01 Face to face dimensions for flanged Globe-style control valve bodies (Class 125,150,300 and 600) 75.08.02 Face to face dimensions for flangeless control valve (Class 150,300 and 600) 75.08.04 Face to face dimensions for Buttweld-end globe style control valve (Class 4500) 75.08.05 Face to face dimensions for Buttweld-end globe style control valve (Class 150,300,600,900,1500 and 2500) 75.08.06 Face to face dimensions for flanged Globe-style control valve bodies (Class 90,1500 and 2500) 75.11.01 Inherent flow characteristic and Rangeability of control valves. 75.19.01 Hydrostatic testing of control valves. 75.22 Face to centre-line dimensions for flanged Globe- style Angle control valve bodies (Class 150,300 and 600) 75.25.01 Test Procedure for Control valve response ‘measurement for step inputs TR 75.25.02 Control valve response measurement for step inputs 75.13 Method of evaluating the performance of positioners with analog input signals and pneumatic output. MSS SP 25 _ Standard Marking System for valves, fittings, flanges and Unions NACE MRO103_— Materials Resistant to Sulphide stress Cracking in Corrosive Petroleum Refining Environments. OSHA Occupational Safety and Health Authority. 113 In the event of any conflict between this standard specification, data sheets, statutory regulations, related standards, codes etc., the following order of priority shall govern: Format No, 6.00-0001-F1 Rev. 0 ‘Copyright EI. — Alrights reserved[STANDARD SPECIFICATION No. eSBBSRRB. “ugeesremme er nee . Page 6 of 22 a) Statutory regulations b) Job specification/data sheets °) Standard specification a) ‘Codes and standards 1.14 Inaddition to meeting purchaser's specifications in totality, vendor's extent of responsibility shall also include the following: a) » ce) 4 12 Bids Purchaser's data sheets specify the minimum acceptable materials for the on-off valve body and trim. Alternate superior materials of construction shall also be acceptable provided vendor assumes complete responsibility for proper selection of ‘material for these parts for their compatibility with the process fluid and its ‘operating conditions. Purchaser's data sheets specify the on-off valve size and open / close operation time, Vendor shall be responsible for selecting their standard valve suitable for the specified service and process conditions and operation time specified in the purchaser's data sheets. Selection of actuator to meet the shut off differential pressure and fire safe requirements indicated in the purchaser's data sheets. Checking of noise generated and providing suitable trim and treatment to limit, these within appropriate limits, whenever specifically indicated in the purchaser's data sheets, 1.2.1 Vendor's quotation shall be strictly as per the bidding instructions to vendor attached with ‘the material requisition. 1.2.2 Whenever a detailed technical offer is required, vendor's quotation shall include the following: a) b) °) ‘Compliance to the specifications. Whenever the requirements of a detailed specification sheet for each on-off valve is specifically indicated, the specification sheet shall provide information regarding type, material of construction, capacity, open/close operation time etc. of the on-off valve and its accessories. The material specifications and units of measurement indicated in the specification sheet shall be to the same standards as those in purchaser’s data sheet. Proven references for each offered model, in line with clause no. 1.2.4 of this specification, specifically for valves with ANSI rating 600# and above, temperature more than 250°C and below -29°C , special applications like hydrogen, NACE, cryogenic, fire safe and metal seated valves with class VI leakage ete. Format No. 6.00-0001-F1 Rev. 0 ‘Conyight EI Al ights eservessar teieies' ad 9 ) 8) by [STANDARD SPECIFICATION No. BAB amrensrren oor aee Page 7of 22 A copy of approval for items such as limit switches, solenoid valves, electro- pneumatic converters, smart positioner, whenever specified from local statutory authority, as applicable, such as Petroleum && Explosives Safety Organisation (PESO) / Chief Controller of Explosives, Nagpur (CCE) or Director General of Mining Safety (DGMS) in India, along with: i) Test certificate from recognised test house like CMRUERTL ete. for flameproof enclosure and/ or intrinsie safety, as specified in the data sheet, as per relevant Indian Standard for all Indian manufactured equipments. ii) Certificate of conformity from agencies like LCIE, Bascefa , PTB, CSA, UL etc. for compliance to ATEX directives or equivalent recognised standards for all equipments manufactured outside India. ‘Type test certificate for fire safety for on-off valve and of actuator, wherever applicable. Limitation, if any, in changing actuator orientation at site. Deviations on technical requirements shall not be entertained. In case vendor has any valid technical reason, they must include a list of deviations tag number wise, summing up all the deviations from the purchaser's data sheets and other technical specification along with the technical reasons for each of these deviations. Catalogues giving detailed technical specifications, model decoding details and other technical information for each type of on-off valve and accessories covered in the bid. 1.2.3. For valves in cryogenic service, vendor shall meet the following acceptance criteria: a) b) ‘Vendor shall furnish, along with the offer, type test certificate, duly witnessed by Third Party Inspection agency like M/S LRIS, DNV, BV,TUV ete. of having successfully conducted the cryogenic test as per BS6364 on the offered valves(same model, size, rating and material) in cryogenic service. In case vendor does not have cryogenic type test certificate for the offered valves ‘as mentioned above, vendor shall conduct the cryogenic test on each of the offered valves as per clause 4.5 of this specification and shall meet one of the following requirements 4) Vendor has successfully carried out the cryogenic type test as per BS-6364 on the same series(model) of the valves as offered and type test certificate duly witnessed by Third party Inspection agency for same has been furnished with the offer. ii) Vendor has furnished proven references as per clause 1.2.4 of this specification for each of the offered valves ( same model, size, rating and material) in cryogenic service, 12.4 All items, as offered, shall be field proven and should have been operating satisfactorily individually for a period of minimum 4000 hours on the bid due date in the process conditions Format No. &-00-0001-Fi Rev. 0 Conyight EL ~ Al ights reservedENGINEERS PECIFICATION SIRS NG Ne ‘STANDARD SPECI 125 1.26 1.27 127.1 13 13.1 132 STANDARD SPECIFICATION No. FOR ON-OFF VALVES 6-52-0037 Rev. 0 Page 8.of 2 similar to those as specified in the purchaser's data sheets. Items with proto-type design or items not meeting provenness criteria specified above shall not be offered. Whenever specified, vendor must furnish certified values of failure rates, probability of failure ‘on demand (PFD) and test intervals for valve and its accessories for the safety integrity level analysis. All documentation submitted by the vendor including their quotation, catalogues, drawings, installation, operation and maintenance manuals etc., shall be in English language only. Vendor's quote shall include the following: a) Universal hand held configurator (HHC) for configuration and maintenance of smart positioner with HART output when specified, b) Valve diagnostic package for seat ring, gland packing and actuator diagnostic for smart positioner, when specified ° Two years’ operational spares for each on-off valve and its accessories, which shall include plug, seat ring, gasket set, packing set, diaphragm, o-ring set etc. as a ‘minimum, 4) Any special tools needed for maintenance work. In case no special tools are necessary for the offered on-off valves and their accessories, vendor must certify the same in their offer. Each valve quoted shall include the following: a) One extra set of packing and bonnet gasket with each tag. b) One extra set of stem seal o-rings for each actuator and piston o-rings additionally for each piston actuator, ° Seat insert (soft part) for each ball valve. 4 Line bolting (set of studs and nuts) and set of gasket, in case of flangeless valves as per material given in Annexure-I and Annexure-2 with each such tag number Drawing and Data Detailed drawings, data, catalogues and manuals required from the vendor are indicated by the purchaser in vendor data requirement sheets. The required number of reproducible, prints and soft copies should be dispatched to the address mentioned, adhering to the time limits indicated. Final documentation consisting of design data, installation manual, operation and ‘maintenance manual etc., submitted by the vendor after placement of purchase order shall include the following, as a minimum: a) Specification sheet for each on-off valve and its accessories. b) Certified drawings for each on-off valve and its accessories, which shall provide dimensional details (face-to-face and height of completely assembled valve), hook- up and wiring details, dimensions of clearance space for maintenance work, weight of completely assembled valve, internal constructional details, materials of Format No. &-00-0001-F1 Rev. 0 Conyight EL — Al rons reserved_SGHeIzIeT ay ENGINEERS, ‘STANDARD SPECIFICATION Tee ON UMITED 2.0 21 241 212 213 214 2.15 2.1.6 247 2.4.7.1 21.7.2 2.1.8 2.1.8.1 STANDARD SPECIFICATION No. FOR ON-OFF VALVES 6-52-0037 Rev. 0 Page 9 of 22 construction and actuator orientation with respect to flow direction marked on the body. ° Copy of the type test certificates. 4) —_Copy of the test certificates for all tests indicated in clause 4.0 of this specification. ° Installation procedure for on-off valves and their accessories. by) Calibration and maintenance procedures including replacement of its parts / internals wherever applicable. g) _ Valve operating signatures whenever smart positioners are specified with on-off valves. hh) _Device Descriptor Files(DD) for configuring smart positioner parameters DESIGN AND CONSTRUCTION Body On-off valves shall have flanged end connections integral to the valve body. Top entry valve design shall not be offered unless specifically indicated in the purchaser's data sheets. Whenever flangeless on-off valve body design is specified in the purchaser's data sheet, following shall apply: a) Water type or lug type body design for on-off valves body size up to 6 inches. ») Lug type body design for butterfly type of on-off valve body size more than 6 inches. However, for on-off valves with fire safe design, flanged body construction shall only be acceptable. Unless specifically indicated otherwise, the minimum on-off valve body size shall be 1 inch. ‘The valve body rating shall be equal to or higher than the flange rating specified in the data sheets. As a minimum, on-off valve body shall be rated for 300# class as per ANSI, ‘however end connection shall be as specified in purchaser's data sheet. ‘The on-off valves shall be suitable for installation in horizontal as well as in vertical lines. For all services where full port valves are specified, following shall apply: a) Port size shall be equal to line size for rating upto ANSI 1500# class. b) Port size shall not be less than one size than the line size for rating ANSI 2500# and above. For steam jacketed valves, the body and port size shall be one size lower than the on-off valve end connections. Flow Direction Flow direction shall be clearly marked on the on-off valve body preferably either stamped or cast on the valve body. 3-way on-off valves shall be clearly identified with inlet and outlet end connection. End Connections Unless otherwise mentioned, end connection details shall be as below: Format No, &-00-0001-F1 Rev. 0 Conyight EI. — All rights reservedSSifeizTeT a ENGINEERS, ‘STANDARD SPECIFICATION Tee SAD 2182 2.1.83 2.1.9 2.1.9.1 2.1.9.2 2.1.93 2.1.94 2.1.9.5 22 2.2.1 22.2 [STANDARD SPECIFICATION No. FOR ON-OFF VALVES. 6-52-0037 Rev. 0 Page 10 of 22 a) ‘Threaded end connections shall be NPT as per ANSVASME B1.20.1. b) _Flanged end connections shall be as per ANSVASME B 16.5 or B 16.47-B or AWWA C207 CLD , as specified in datasheet. ©) _ Flanged face finish shall be serrated concentric as per clauses 6.4.4.1, 6.4.4.2 and 6.4.4.3 of ANSIB 16.5. The face finish as specified in the data sheets shall be as follows: 125AARH: 125 to 250 AARH 63 AARH 32 to 63 AARH. 4 Ring type joint flanges shall have octagonal grooves as per ANSI B 16.20. Face-to-face dimensions of on-off valves shall be in accordance with the relevant standard indicated in clause 1.1.2 of this standard specification. Where provided, on-off valve bottom drains shall be plugged off or blind flanged. Where a plug is used, threads shall correspond to ANSVASME B 1.20.1 (NPT). Where a flange is used, its dimensions and rating shall correspond to ANSI/ASME B16.5. Material of Construction ‘The material of construction of on-off valves shall be as specified in the data sheet. No material shall be substituted by vendor without specific written approval from purchaser. On-off valve body, bonnet, bottom flange, line flanges and other pressure containing assemblies shall be of the same material of construction as specified for valve body in the purchaser's data sheets, ‘The bonnet flange and bottom flange shall have metallic spiral wound gaskets suitable for the specified service. The gaskets with asbestos bearing fillers shall not be used. Vendor shall be responsible for selecting proper material for the internal parts of on-off. valve which shall have the same or better material specifications and compatible with the process fluid and conditions specified in the purchaser's data sheets. ‘The material of construction of silencers, diffuser plates, diffuser plate assembly etc, when specified, shall be as per the body material specified in the purchaser's sheets, as a minimum. Trim The term ‘trim’ covers those parts of valve assembly (excluding the body, bonnet and bottom flange) which are exposed to and are in contact with the line medium consisting of but not limited to the seat ring, valve stem, valve plug/disc/ball, valve plug guide, cage guide bushing ete. In case of ball-type of on-off valves; a) The valve design shall ensure valve seat and body protection against thermal expansion of the entrapped fluid when the on-off valve is fully close. Format No, &-00-0001-Fi Rev. 0 Copyright EIL— Alrrighs reserved‘STANDARD SPECIFICATION No. ENGINEERS, STANDARD SPECIFICATION eats ONAN FOR ON-OFF VALVES. 6-52-0037 Rev.0 Page 11 of22 b) For size upto 3" and rating 300# ,the on-off valve shall have floating ball design. 2.23 223.1 2.2.3.2 2.2.3.3 224 2.2.4.1 2.2.4.2 22.5 2.2.5.1 For valve sizes 4” and above and rating higher than 300#, the on-off valve shall have trunnion supported ball design. Guiding Single seated globe (unbalanced) and angle type on-off valves shall have heavy top plug guiding. Stem guided on-off valve design shall not be acceptable. Rotary type on-off valves like Ball valves, butterfly valves ete. shall have blow out proof shaft guiding design. Guide bushing shall be of a sufficiently hard material to resist side thrust on the plug or shaft Trim Design Vendor shall be responsible for trim design and selection of the on-off valve. However, it ‘must meet the following minimum requirements: a) On-off valve trim design shall suit the type of guiding specified in the data sheet. D) Unless specifically indicated otherwise in purchaser's data sheets, the valve characteristics shall be quick-opening (on-off) type. ° Vendor shall select proper material pairs, surface finish, hardness and clearances to avoid galling. @) For on-off valves operating under extreme temperature conditions, vendor shall consider increased clearances at room temperature and seal welding of threaded seat rings etc whenever required. Hard facing of trim including guide bushing shall be considered for all on-off valves operating at high temperatures (i.e. temperature more than 200°C). For very low temperature application, material used shall have adequate cold impact strength. ° For all on-off valves including 3-way type of valves, stem and plug shall be detachable and shall be attached together by suitable threaded design secured with a pin to avoid plug rotation during operation. ) Whenever the possibility of aerodynamic noise in a control valve exists under any operating condition specified in purchaser’s data sheet, vendor shall select a special low noise trim for that application. For all bi-directional types of on-off valves like ball, butterfly and plug type, the valve seat design shall provide tight shut off for flow in either directions. ‘Trim Material Whenever stellited trim is specified in the data sheets following material of construction for the trim parts shall be acceptable. a) __Ball/Disc/Plug and seat. _Stellite sheathing/hard alloy coating or solid stellite b) Guide Stellite sheathing/hard alloy coating, solid stellite or $8 4406 Format No, &-00-0001-F7 Rev. 0 ‘Copyright EIL — Al ighis reserved‘STANDARD SPECIFICATION No. ENGINEERS STANDARD SPECIFICATION eames ORR UMITED FOR ON-OFF VALVES 6-52-0037 Rev. 0 Nestea mae ©) Stem/Shaft 17-4 PHSS, Hastelloy 2.2.5.2 Whenever hardened stainless steel trim is specified in the purchaser’s data sheet, following 2.2.5.3 22.5.8 22.55 2.2.5.6 23 23.1 23.2 233 24 2.4.1 24.1.1 material of construction for the trim parts shall be acceptable provided same are compatible with the specified process conditions; a) Ball/disc/Plug and seat _Stellite sheath /hard alloy coating, solid stellite,17- APH Stainless Steel or SS 440C b) Guide Stellite sheath /hard alloy coating, solid stellite,17- APH Stainless Steel or SS 440C ©) Stem 17-4 PH Stainless Steel, Hastelloy Minimum acceptable hardness in case of stellited or hardened trim shall be of the order of RC38 (BHN 352) to RC45 (BHN 429), In case of rotary valves, vendor shall select the stem bearing type and material as per the process conditions. Material of construction shall be as per the wetted part material specified in the purchaser's data sheet, as a minimum, Leakage class of on-off valves shall be as specified in purchaser's data sheet, where no class is specified in data sheet it shall be Class IV. For on-off valves specified with Class VI leakage class, vendor shall select the soft seat (elastomer) material suitable for the process conditions i.¢., shut off pressure, maximum temperature and process fluid, Metal seated on-off valves meeting the leakage class shall also be acceptable. Sizing Unless specifically indicated otherwise in purchasers data sheet, no sizing shall be carried out for the on-off valve, body size of on-off valve shall be same as the line size. Valve sizing shall be carried out only for those on-off valves where purchaser data sheet specify the same. Vendor shall indicate the offered on-off valve flow coefficient ie. Cv . Wherever the ‘requirement of valve sizing is indicated , the control valve capacities in terms of Cv when shown in the purchaser's data sheets have been arrived at using the formulae given in the standard ANSV/ISA S 75.01.01-"Control valve sizing equations”. In case vendor's sizing formulae differ from above, purchaser shall be provided with the details. Rangeability of valves shall be as per manufacturers’ standard. However, where purchaser's data sheet indicate the sizing requirement, the rangeability of the offered valves shall be suitable to meet specified rangeability. Packing Box, Bonnet and Stem Packing Box = e packing box shall be flanged bolted to the bonnet and shall meet the requirements specified in purchaser's data sheet. Format No, 8-00-0001-F1 Rev. 0| Copyright EIL— Allvighis reserves[STANDARD SPECIFICATION No. ENGINEERS, STANDARD SPECIFICATION eee Mn UMITED FOR ON-OFF VALVES. 6-52-0037 Rev. 0 Te natennoe nanan 24.1.2. Generally low friction type packing like braided teflon is preferred wherever operating 2.4.3.2. 2.4.3.3. 25 25.1 25.11 2.5.1.2 conditions permit. For high temperature application (200°), Grafoil or equivalent gasket suitable for the specified service shall be selected. Asbestos based packing material shall not be used. Whenever the on-off valve is offered with external lubricator, it shall have its packing box drilled and tapped to 1/4" NPT (F) as per ANSVASME B 1.20.1 for connecting external lubricator. ‘An isolating valve shall be provided with all such valves having extemal lubrication provision. Lubricator sticks shall be supplied by the vendor as consumable spare. For application in vacuum service, vendor to provide inverted packing design suitable for vacuum service. For pressure-cum-vacuum service, the on-off valve shall have dual packing design suitable for the application. Dual packing design shall also be provided for on-off valves in toxic service, with a facility to connect inert fluid between the packings. Wherever environmental packing design is specified vendor shall supply special packing design suitable to minimize fugitive emission. 3-way on-off valves of either diverting or mixing type shall have PTFE box rings. Bonnet ‘The bonnet shall be flanged bolted to the body. Threaded bonnets are not permitted. Wherever the operating temperature of the fluid is above 200°C, extension or radiation finned bonnet shall be provided. Vendor standard bonnet design shall also be acceptable if these are suitable for higher temperatures. For temperature below 0°C, vendor shall provide extended bonnet design. For valves in cryogenic application bonnet extension shall be as per BS-6364 as a minimum, Stem ‘The stem surface finish shall be fine, Extra fine surface finish shall be provided wherever the packing material is PTFE. The stem/shaft shall be designed for the maximum thrust of the actuator without any measurable deflection. The valve stenvshaft shall be connected to the actuator stenvshaft by suitable arrangement to avoid backlash problem. Actuator Pneumatic Actuator Actuator shall be sized for the shut-off differential pressure indicated in purchaser’s data sheets. However, for 3-way type on-off valve, the actuator shall be sized for maximum differential pressure, unless specifically indicated otherwise. The actuator shall be designed to move the valve to the failure position specified in the purchaser’s data sheet, For failure position specified as ‘fail-locked’, vendor shall provide air reservoir with all required accessories to meet the fail lock position of the valve. The air Format No, &-00-0007-F1 Rev. 0 Copyright EIL— All vighis reservedSOeIZIET i ENGINEERS, STANDARD SPECIFICATION a) 25.13 25.14 25.15 25.16 2.5.1.7 2.5.1.8 25.1.9 2.5.1.10 2.51.11 2.51.12 251.13 ‘STANDARD SPECIFICATION No. INDIA UMITED FOR ON-OFF VALVES 6-62-0037 Rev. 0 Page 14 2 reservoir shall be sized considering full stroking of the valve for minimum one complete cycle. Air reservoir shall be of carbon construction and sized as per ASME Section VIII with design pressure of 10 kg/em2g as a minimum. All accessories and tubing shall be SS 316. Actuator casing shall be made of pressed steel or anodised aluminium. Non-metallic actuator casings shall not be offered. Springs shall be corrosion-resistant and shall be cadmium or nickel-plated. These shall be of the enclosed type. ‘The compression of the springs shall be adjustable In general, actuator operating range shall be 0.2 to 1.0 kg/em’g, higher actuator operating range shall be acceptable provided vendor standard actuator model fails to meet specified shutoff pressure. In general, spring opposed diaphragms type actuators shall be used. Only when this type of actuator becomes extremely unwieldy, based on the data specified in the purchaser’s data sheet, should a piston and cylinder type of actuator be considered. Whenever piston and cylinder actuator is considered, single acting spring return type is preferred, Whenever double acting springless type of actuator is unavoidable, all accessories like pilot valves, booster relays, non-return valve, pressure gauge, volume tank etc. shall be provided to ensure desired action on air failure. The volume tank shall be sized considering full stroking of the valve for three complete cycles. ‘The volume tank shall be of carbon steel construction and sized as per ASME Section VIII with design pressure of 10kg/cm’g as a minimum. All accessories and tubing ete shall be of 316 Stainless Steel constructions. ‘The actuator casings and diaphragms shall be designed for minimum twice the maximum pneumatic operating pressure of the on-off valve. Valve stem position indicator shall be provided for every on-off valve. The position indicator scale shall be calibrated from 0 to 100%. In general, side-mounted handwheels are preferred. Hand wheels shall provide manual on- off in both opening and closing directions independent of spring action. Hand wheels shall be of non-rising type suitable for accurate valve positioning .The hand wheel actuator shall be sized to provide the required thrust for valve positioning with 178N force applied to the hand wheel. Actuator orientation shall be as per purchaser's requirements, in general. When, no requirements are indicated by purchaser, vendor shall provide recommended actuator orientation. It shall be possible to change this orientation at site for the offered valve- actuator combination in case it is found necessary. For the on-off valves where operating times are specified in the purchaser's data sheets, vendor shall design the actuator and its accessories to meet these requirements. Format No, 6-00-0001-Fi Rev. 0 ‘Copyright EIL ~All rghis resenesSG zIe% i ENCINEERS, STANDARD SPECIFICATION Te ONT UMITED. STANDARD SPECIFICATION No. FOR ON-OFF VALVES 6-52-0037 Rev. 0 ‘Rae i Page 166422 2.51.14 Actuator Sizing 26 2.6.1 2.62 27 2.7.1 a) b) Vendor shall be fully responsible for sizing and selection of correct actuator for the specified on-off valve, while sizing the actuator, vendor shall ensure that the actuator is able to develop sufficient thrust to properly seat the on-off valve at the lowest specified air pressure, While sizing the actuator vendor shall consider actuator thrust equal to two times (2) the total force induced by shut off condition specified in purchaser's data sheet and the force required to overcome packing friction. Valve Jacketing ‘The jacketed valves shall have steam inlevVoutlet connections as flanged. ‘The valve end connections shall be one size higher than the normal valve connections for jacketed valve Accessories ‘Smart Type Positioners Digital SMART positioners with diagnostic capabilities shall be supplied whenever specified in purchaser’s datasheet. These shall meet the following minimum requirements: ”) » °) d 8) hy hy The positioners shall be direct acting, with an adjustable gain unless otherwise specified. Every positioner shall have two pressure gauges mounted on it, one each for air supply and for positioner output to actuator. Pneumatic connections shall be 1/4" NPT (F) and cable entry shall be 4” NPTF to ANSV/ASME BI1.20.1. If connection for cable entry is different than that specified, suitable adapters shall be provided Positioners shall be side-mounted on the control valve and shall have corrosion resistant linkages and rugged brackets, unless remote mounted positioner is offered when specified in the purchaser's datasheet. ‘The positioner sensor and sensing mechanism shall be rugged and shall not be effected by the line / valve vibration, The performance of the positioners shall be immune to above vibration The positioner’s output and input range shall be field adjustable without any hardware modification. The output from the positioners shall be available for both single acting as well as double acting actuator. Each positioner shall be operable, configurable and accessible through HART compatible hand held configurator . Smart positioners shall also have a dedicated operating panel for the above functions ‘The positioner shall be @ two-wire device, which shall operate on two-way digital communication mode. All engineering, configuration, diagnostic and maintenance related data shall be provided by the positioner. Format No, &-00-0007-F1 Rev. 0| ‘Copyright EL Allrighis reserved‘STANDARD SPECIFICATION No. ENGINEERS STANDARD SPECIFICATION wi ORR UMITED. FOR ON-OFF VALVES 6-52-0037 Rev. 0 2.72 2724 2.7.2.2 2.73 2.73.1 2.73.2 Page 16 of 22 i) ‘The smart positioner shall provide HART protocol of latest version and shall be capable of implementing commands from HART maintenance systenvhand-held HART configurator. i The positioners shall be suitable to operate with commercially available asset management softwares and shall support the following features, as a minimum: i) Tt shall allow multimaster for configuration, calibration, diagnosis and maintenance. The primary could be a host computer and secondary could be a hand held communicator. ii) It shall be capable of implementing universal commands. It shall be possible to communicate all commands of commercially available asset ‘management system to/ from smart positioner. ® ‘The offered positioners shall meet the following performance characteristics: - i) Overall accuracy shall be better that +0.5% of span. ii) Repeatability shall be less than + 0.25% of span. iii) Hysteresis shall be less than + 0.5% of span. iv) Vendor shall supply the valve’s operating signatures in the form of hard copy and CD for each control valve supplied with smart positioners. ‘The necessary software for advanced control valve diagnostics like seat ring condition, gland packing condition, actuator leakage etc. shall also be included, , ) All positioners shall have metallic casing and cover either of stainless steel or of anodized aluminium. Air Filter Regulator Vendor shall supply air filter regulator with each positioner complete with an integral output gauge. Air filter regulator shall be sized considering the air supply pressure and flow required to mect requirements specified in the purchaser’s data sheets. Filter material shall be sintered bronze. Filter size shall be maximum 5 microns. However, lower filter mesh size shall be considered to suit the electro pneumatic converter vendor's requirement. Limit Switches Unless otherwise specified, limit switches shall be proximity type. Mechanical type limit switches shall only be used when specifically indicated. Mechanical type limit switches when used shall meet the following contact requirements: (i) Contact type- Double pole Double throw (DPDT), sealed type (ii)Contact material- Copper with Tungsten Carbide or copper with gold plated (for intrinsically safe system) Format No. 6-00-0007-F1 Rev. 0| Copyright EL — Al rights reserved‘SGitetzTey as ENGINEERS, STANDARD SPECIFICATION Gees @ NSAID 274 28 28.1 2.8.2 29 2.9.1 2.9.1.1 STANDARD SPECIFICATION No. FOR ON-OFF VALVES 6-52-0037 Rev. 0 Page 17 of 22 (ii)Contact rating- 110 V DC 0.5 Amp/230 V AC 5 Amp or 30 V DC 100 mA( for intrinsically safe system) Hand held configurator for Smart Instruments Hand held configurator shall be universal type and shall be able to communicate with all make and models of smart instruments with HART output like transmitters, smart positioners ete., and shall be capable of carrying out all engineering functions like calibration, configuration and diagnostics. The hand held configurator shall be certified intrinsically safe when used in hazardous area. Carrying case shall be supplied with each configurator. Finish The body shall be painted as below: Carbon steel body - Light grey Alloy steel body = Canary yellow Stainless steel body = Natural Above 150°C - Aluminium paint (white colour) Items like silencers, diffuser plate assemblies etc., shall be painted as per respective on-off valve body requirements. The actuator shall be painted as below: Direct action (open on air failure) valves - green Reverse acting (close on air failure) valve - yellow Actuator for shutdown valves - red Items like air volume tanks ete., supplied as an accessory along with the actuators, shall be painted as per corresponding actuator. Special Requirements: On-Off Valve stroke testing: Whenever specified in the purchaser data sheet / specifications, the operational integrity of the on-off valves shall be verified at regular intervals by performing physical testing without upsetting the process / operation. The methodology of testing adopted shall also be indicated in the purchaser's data sheets. The testing scheme shall be designed by the vendor to meet specified operational functional and safety requirements specified below; ‘Manual Valve Testing (MVT) Manual valve testing scheme shall be designed by the vendor to ensure operational integrity of actuating components i.e. solenoid valves ete without stroking the on-off valve. The test hardware shall meet the following requirements; ‘The manual valve testing scheme shall be designed and supplied complete with minimum two solenoid valves, a two position (normal test) manual switch (with lock) and a pressure gauge (50mm dial). The scheme shall meet the following functional requirements, Format No. &-00-0001-F1 Rev. 0 ‘CopyightEIL — Al ighis reservedSSIES aS ENGINEERS, STANDARD SPECIFICATION sBarfetsies NDIA LIMITED 2.9.1.2 2.9.2.1 2.9.2.2 ‘STANDARD SPECIFICATION No. FOR ON-OFF VALVES 6-52-0037 Rev. 0 Page 18 of 22 a) There shall be no upset or disturbance in the process while carrying out MVT. The solenoid valves, therefore shall be pneumatically tubed in 2 out of 2 configuration. While in test mode, the switch shall supply air supply to actuator bypassing the accessories. The solenoid valves are manually actuated one by one with their operational status indicated by pressure gauge. b) No software for MVT is in vendor’s scope, however, an electrical contact rated for 110V, 0.5 A DC shall be provided to purchaser for audit trail when in test position. Partial Stroke Testing (PST) Partial stroke testing shall be performed to ensure satisfactory operation of on-off valve including all accessories on demand. The test shall be performed automatically by partially (around 10%) stroking the valve while these valves are in service. ‘The test hardware and software shall meet the following minimum requirements; a) Partial stroke test scheme shall be complete with all hardware and softwares which shall include solenoid valves, valve positioner and logic solver. All components used in PST shall be fail safe and shall not affect the on-off valve performance under any circumstances. b) The PST design shall ensure; i)The testing shall be carried out automatically at pre-defined intervals which shall be adjustable, ii)The shutdown demand shall always over-ride if PST is in operation at that time. iii)The valve shall not operate beyond a predefined maximum allowable stroke valve under any condition or failure. When valve positioner is used to realise PST, the positioner output shall be limited beyond the allowable value in case of valve struck condition, iv)Audit trail shall be available to indicate time and date of PST, test results (OK / fail), reason of failure, changes made ete asa minimum. v)Upward connectivity to purchaser’s Host system, Vendor shall supply the complete testing assembly duly tubed / piped / wired on a SS mounting plate of thickness 3.2mm suitable for 2" pipe stanchion mounting. Standard pre designed rigidly mounted components shall also be acceptable for PST assembly. Fire Safe Design Requirements Wherever the valves are indicated as fire safe on the data sheets they shall be tested for fire safe as per BS-6755 (Part-2) when the valves are supplied with metal-to-metal seats and shall be tested as per API 607 latest edition when the valves are provided with soft seats. In case soft-seated valves with fire safe design are offered, vendor’s design shall be such that soft seat is not damaged while closing/opening of the valve. Wherever fire safe actuator and controls have been asked for, actuators and all accessories such as solenoid valves, air volume bottles etc. shall meet the fire proof requirement to Format No 8-00-0007-F1 Rev. 0 Copyright EL — All Rights reservedSTANDARD SPECIFICATION No. SORGIZIES a ENGINEERS ‘STANDARD SPECIFICATION eateee ONAtED FOR ON-OFF VALVES 6-52-0037 Rev. 0 Nearer eae 29.2.3 2.9.2.4 2.93 3.0 eT ensure normal valve operation even during and after exposure to fire. Vendor shall clearly define the schemes they propose to achieve the above requirements and ensure that the proposed schemes shall meet the requirement in terms of type of exposure and exposure time of the testing procedure given in BS-6755/API 607. Vendor must note that all items i.e. actuators, its accessories and interconnecting tubing including Volume bottles is required to be protected under fire exposure conditions. The fire protection methodologies like fully enclosed fireboxes or special material coverage are acceptable provided fire safe certification is provided for complete assembly as indicated above. Vendor shall furnish type test certificate duly witnessed by third party inspection agency like MIS LRIS,BV,DNV,TUV etc. for fire safe testing of valve, actuator and controls for the offered models along with the offer. Vendor to note that fire safe box upto maximum twice the surface area of fire box already satisfactorily fire safe type tested is acceptable provided the clearance inside the fire box with all accessories duly mounted are maintained equal to or greater than those maintained in fire safe box successfully type tested. In case, earlier fire safe test carried out by vendor is not applicable for quoted size/rating of the valve, fire safe box, then vendor shall carry out the test for fire safe design for the offered valves / actuators & controls Backup volume bottles for the valve operation shall be designed inline with ASME Sec. VIII requirement. Each volume bottle shall be sized for a minimum of 3 valve strokes. Backup bottles shall also meet the requirement of fireproofing in case fireproof actuators and controls have been asked for. Special Service Valves All on-off valves in oxygen and chlorine service shall be thoroughly degreased using, reagents like trichloro-ethylene or carbon tetra-chloride. End connections shall be blinded / plugged after this degreasing process in order to avoid entrance of grease and oil particles. NAMEPLATE, Each on-off valve shall have a stainless steel nameplate attached firmly to it at a visible place, furnishing the following information: a) Tag number as per purchaser's data sheet. b) Body and port sizes in inches. ©) Stem travel in millimetres. Action on air failure. ©) Spring range. ) Air supply pressure £) Manufacturer's mode! number for the valve body, actuator and positioner. Format No, 8.00-0007-F1 Rev. 0 ‘Copyright EL — AI rants reserved‘STANDARD SPECIFICATION No. efBEORNRi vapeereren Door eens = Page 20 of 22 4.0 INSPECTION AND TESTING 4.1 Unless otherwise specified, purchaser reserves the right to test and inspect all the items at the vendor's works, in line with inspection test plan for on-off valves. 4.2 Vendor shall submit following test certificates and test reports for purchaser's review: 8) Material test certificate as per Type 3.1 of EN 10204 for each valve body, bonnet castings! forgings and as per Type 2.2 of EN 10204 for trim. b) Certificate of radiography/X-ray for valve castings wherever specified in valve data sheets. 100% radiography shall be carried out for the following valve castings: i) Body sizes 18” and above. ii) Body rating ANSI 600 pounds and above. Radiography procedure shall be as per ANSI B16.34 and acceptance shall be as per ANSTBI6.34 Annexure-B. ° Pneumatic test certificate for all pneumatic actuator at a pressure not less than one and half (1.5) times the actuator working pressure. 4) BR certificate in form III C for all valves covered under IBR certification. ©) Dimensional, hydrostatic test reports for all valve bodies and functional test reports for all valves as per clause 4.3 and 4.4 of this specification 1) Certificate of intrinsic safety/explosion proof from statutory body for smart positioners, limit switches, solenoid valves etc. 8) _ Type test certificate for fire safety for fire safe valve and its actuator and controls. 1h) Type test cettificate for valves in cryogenic service as per clause 4.5 of this specification. 43 Hydrostatic Test 43.1 Each on-off valve body shall be subjected to hydrostatic test pressure equal to 1.5 times the maximum working pressure at ambient temperature in accordance with ANSI B16.34, All on-off valve bodies covered under IBR, shall be tested as per IBR regulations. There shall not be any visible leakage during this test. 44 Functional Tests 44.1 Seat Leakage Test The test shall meet the requirements given in ANSVFCT 70-2 for the specified seat leakage class. 44.2 Lift Characteristics 4.4.2.1 The test shall be carried out at no load condition for the verification of stem travel. 4.4.2.2. The combined effect of linearity and hysteresis shall be better than the following: 8) 1.0% of rated lift with smart positioner. be .0% without positioner 4.4.3 Tests on smart positioners Following tests shall be carried out on smart positioners: Format No. €-00-0007-F1 Rev. 0 ‘Copyright EIL— Allrghis reseedSGTfetzTE ga ENGNEERS. STANDARD SPECIFICATION s8ar Pees SNA Iii ‘STANDARD SPECIFICATION No. a elses Sa NDIA LIMITEL FOR ON-OFF VALVES 6-62-0037 Rev. 0 Page 21 of 22 a) Configuration verification as per purchaser's specifications. bv) _ Performance characteristics verification meeting requirements specified in clause 2.7.1 (&) of this specifications. ©) Valve and positioner diagnostics using valve positioner diagnostic software. 4) Valve failure position in case of positioner failure. Positioner failure shall be 444 445 45 46 461 462 5.0 51 52 53 34 simulated considering air failure, signal failure etc. On-off valve response time verification wherever specified as per ANSV/ISA 75.25. Open-close operation time of the valve against full shut off pressure specified in the purchaser’s data sheets, Cryogenic Test, Cryogenic test on each valve in cryogenic service shall be carried out as per BS6364 . Test ied in datasheets shall be (-)45 deg C for low temperature carbon steel(LTCS) and (-) 196 deg C for all grades of austentic stainless steel temperature, unless otherwise speci Witness Inspection Vendor shall offer all values for pre-dispatch inspection and following tests/checks shall be carried out as a minimum, 8) _ Physical dimensional verification and workmanship. 1b) —_ Hydrostatic test as per clause 4.3 of this specification on representative samples ©) _Funetional tests as per clause 4.4 of this specification on representative samples. 4) —_ Pneumatic test on actuator on representative samples. ©) Cryogenic test on valves as per clause 4.5 of this specification ,in case type test certificate duly witnessed by Third Party Inspection agency for same is not furnished by vendor. b) Review of all certificates and test reports as indicated in clause 4.2 of this specification. In the event when no witness inspection is carried out by purchaser, the tests shall anyway be completed by vendor and documents for the same shall be submitted to purchaser for scrutiny. SHIPPING ‘The on-off valve and its accessories shall be supplied pre-assembled and pre-tubed All threaded and flanged openings shall be suitably protected to prevent entry of foreign material. Valves with extemal lubricators shall be lubricated prior to shipment. Valves in oxygen and chlorine service shall be packed separately along with a certificate indicating ‘CERTIFIED FOR OXYGEN / CHLORINE SERVIC E', as applicable. Format No, &:00-0001-F1 Rev. 0 Copyright EL — All ights reservedSERGI A ENGINEERS STANDARD SPECIFICATION ST*NPARD SPECIFICATION No, sar felsic NDIA UMITED FOR ON-OFF VALVES 6-52-0037 Rev. 0 Page 22 of 22 60 REJECTION 6.1 Vendor shall prepare their offer strictly as per clause 1.2 of this specification and shall attach only those documents and information, which is specifically indicated in the material requisition, 62 Anyoffernot conforming to above requirements shall be summarily rejected. Format No. 8:00-0007-F1 Rev, 0 ‘Copyright EIL— Allvighis reservedSmI ENCNEERS STUD-BOLTS AND NUTS Annexure 1 to ‘STANDARD SPECIFICATION NO. 6-52-0037 Rev. 0 Page 1 of 1 Sr.No. Piping Classes ] ‘Nut and Bolt Material 1 AIA, ADA, ASA, AGA, ATA, ABA, ADA, | A-193 Gr. BT AIOA, ALIA, AIBA, AI4A, AISA, | A-194 Gr. 2H | AI9A, A20A, A32A, A33A, AIK, AGK, AIM, AIN, BIA, B2A, BSA, B6A, BA, | BI3A, BI8A, BI9A, B32A, BIK, B6K, | BI8K, BIM, B3M, BSM, BIN, BON, | DIA, D2A, DSA, DIBA, DIK, DI8K, D18P, E1A, E2A, ESA, ESE, FSA. | AIA, BI6A — | ‘A193 Gr. BIM ‘4-194 Gr, 2HM 3 AIB, AID, A4F, A4G, BIB, BID, BSD, | A1-193 Gr. BI6 BIE, B3F, B4F, B4G, DIB, D2B, DID, | A-194GR.4 2D, DSD, DSE, F2D a 72K, BOK, DIK 4-320 Gr. BS CLD. A-194 Gr. 8 3 ‘AGA, ATH, B4A, BIH, D4A, DIF 4-320 Gr. LT A-194 Gr. 4 6 ABY ‘A307 Gr B A-563 Gr. B 7 ASA, ASK, ABY, AAV, BA A307 Gr. B A-563 Gr. B eee 8 ‘AIZ, AQZ, ASY, ASZ, J2A, ISA ‘4-307 Gr. B (Galvy A-563 Gr. B (Galv) 9 BAK, BSK ‘A-193 Gr. BS MCT ‘A-194 Gr. 8MA. 10 A32¥ ‘A-193 Gr. B (Galy) ‘A-194 Gr. 2H (Galv) iT B3M, BaK, BSK, BSM ‘K-A53 Gr, 660 CLA 4-453 Gr, 660 CLA, Format No. 8-00-0001-F1 Rev. 0 Copyrights EiL— All rights reservedSS BONS GASKETS MATERIAL ‘Annexure 2 to INDIA UMITED REQUIREMENT [STANDARD SPECIFICATION No. sBarklbics (AG of rte nae 6-52-0037 Rev 0 Pago 1 of 1 xe Piping Classes Gasket Material 1 [ AIA, AGA, A9A, AIDA, ATIA, AISA, AMA, ,AI9A, | SP WND $8 316+ CAF ‘AIB, AID, ATH, AIK, AIM, AGA, AGP, AMG, BIA, BIH, B2A, B4A, BGA, BOA, BI3A, BISA, BIDA, B32A, BI8K, DIA, D2A, DIlf, DIK, D4A, DIBA, DISK, DIS? 7 2_| BSM SP WND SS316H+ GRAFIL =IRING 3 [Ane Ba SP WND $5 316-GRAFILASS31610 RING 4 [BIN ‘SP WND $S 316L*GRAFIL + [RING 3_| BON ‘SP WND $S 3161 +GRAFIL ©_| AlZ, ASY, AAY, AAZ, A BUTYL RUBBER 7_| BIA, E2A, BSA, FSA SOFT IRON 8_| ESE, FD 3% CR, 0.5% MO 9_| Bak, BsK ‘SS 316H+GRAFILH RING 85 316 0 RING 0) TAsznneas PTFE JACKETED ASBESTOS 11_| ASY, ABA, AISA, AS2Y, A33Y ~ fis272 Ge alt 2 [BM ‘SP WND SS 321+GRAFILH RING AIN, AOK, A16A, BI6A, ‘SP WND SS 316+ CAF ABA, ABK, A33A, IBA, ISA 1S 2712 Gr. W3. ‘A2A, A20A, A32A_ 182712 Gr. Wi ASA, BSA, DSA ATA, BIB, BID, BIE, BIK, B3P, B4F, B4G,BSD, DIB, DIK, D2B, DID, D2D, DSD, DSE | SP WND SS 316+ CAF +1RING | SP WND SS 316+GRAFIL +1 RING BOK, BIM | S8316+GRAFIL Format No, 8.00-0001-F1 Rev. 0 Copyrights Ell. ~ Al rights reserved