PG-PDS 03-12-09 General Requirements for Valves Sep 2009

SCOPE

[I] This Project Design Specification (PDS) covers general requirements governing the design,
inspection, testing, and preparation for shipment of valves.

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 PG-PDS 03-12-09 General Requirements for Valves Sep 2009

TABLE OF CONTENTS

1. REQUIRED REFERENCES.................................................................................... 4
1.1. PDS – Project Design Specifications........................................................ 4
1.2. API – American Petroleum Institute.......................................................... 4
1.3. ASME – American Society of Mechanical Engineers .............................. 4
1.4. AS – Australian Standards ........................................................................ 5
2. ADDITIONAL REQUIREMENTS ............................................................................ 5
2.1. ASME – American Society of Mechanical Engineers .............................. 5
3. MATERIALS ........................................................................................................... 5

4. DESIGN .................................................................................................................. 5
4.1. Additional Requirements for Valves Equipped with Chainwheels................. 6
5. ADDITIONAL REQUIREMENTS FOR LOW ALLOY VALVES IN HYDROGEN
SERVICE AND AUSTENITIC STAINLESS STEEL VALVES IN HIGH
PRESSURE SERVICE............................................................................................ 7

6. ADDITIONAL REQUIREMENTS FOR VALVES .................................................... 7

6.1. In Wet H2S Service...................................................................................... 7
6.2. In Methanol Service.................................................................................... 9
7. ADDITIONAL REQUIREMENTS FOR COMPACT VALVES REQUIRING
POSTWELD HEAT TREATMENT .......................................................................... 9

8. INSPECTION AND TESTING ............................................................................... 10

9. PREPARATION FOR SHIPMENT ........................................................................ 10

9.1. General Requirements ............................................................................. 10
9.2. Protective Coatings.................................................................................. 10
9.3. Valve Protection ....................................................................................... 11
9.4. Identification and Labeling ...................................................................... 11
ATTACHMENT: PURPOSE CODES DEFINITIONS ................................................... 12

RECORD OF CHANGE ................................................................................................ 13

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1. REQUIRED REFERENCES
[I] This Section lists Practices and Standards that are generically referenced and assumed to be a
part of this document. Unless otherwise specified herein, use the latest edition.

1.1. PDS – Project Design Specifications

PGHU-EH-LSPDS-000101
PGHU-EH-LSPDS-000002
PGHU-EH-ISPDS-000903
PGHU-EH-RSPDS-008304
PGHU-EH-RSPDS-000137
PGHU-EH-RSPDS-000202
PGHU-EH-RSPDS-000101
PGHU-EH-RSPDS-000302
PGHU-EH-RSPDS-000303
PG-PDS 03-01-01 Upstream Piping Component Selection and
System Design
PG-PDS 03-99-03 Test Requirements for Valves in Cryogenic
Service
PG-PDS 15-09-03 Actuators for On/Off Valves
PG-PDS 18-03-04 Pressure Casting Quality and Inspection
PG-PDS 29-01-37 Elastomer and Thermoplastic Selection
Guidelines for Oil and Gas Production
PG-PDS 29-02-03 Painting General Requirements - Onshore
PG-PDS 29-01-01 Upstream Positive Materials Identification
PG-PDS 29-03-02 Upstream Process Piping Welding and Inspection
PG-PDS 29-03-03 Upstream Pressure Vessel Welding and
Inspection

1.2. API – American Petroleum Institute

API SPEC 6A Specification for Wellhead and Christmas Tree Equipment

API SPEC 6D Petroleum and Natural Gas Industries-Pipeline Transportation Systems-
Pipeline Valves
API STD 594 Check Valves: Flanged, Lug, Wafer and Butt-welding
API STD 598 Valve Inspection and Testing
API STD 599 Metal Plug Valves - Flanged, Threaded and Welding Ends
API STD 600 Bolted Bonnet Steel Gate Valves for Petroleum and Natural Gas
Industries
API STD 602 Steel Gate, Globe and Check Valves for Sizes DN 100 and Smaller for
the Petroleum and Natural Gas Industries
API STD 603 Corrosion-Resistant, Bolted Bonnet Gate Valves - Flanged and Butt-
Welding Ends
API STD 607 Fire Test for Soft-Seated Quarter-Turn Valves
API STD 608 Metal Ball Valves - Flanged, Threaded, and Welding End
API STD 609 Butterfly Valves: Double Flanged, Lug- and Wafer-Type

1.3. ASME – American Society of Mechanical Engineers

ASME B16.34 Valves - Flanged, Threaded, and Welding End

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1.4. AS – Australian Standards

AS 4041 Pressure Piping

2. ADDITIONAL REQUIREMENTS
The following Specifications and Standards shall be used with this PDS.

2.1. ASME – American Society of Mechanical Engineers

ASME B16.5 Pipe Flanges and Flanged Fittings NPS 1/2 Through NPS 24 Metric/Inch
Standard
ASME B16.47 Large Diameter Steel Flanges NPS 26 Through NPS 60
ASME B31.3 Process Piping

2.2. Deleted

3. MATERIALS
1) [R] Austenitic stainless steel and nickel alloy valves (body, bonnet, cover, and cap) shall meet the
following requirements:
a) Trim including stem and seats, gland assemblies including 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, and is always an acceptable alternative
for seating surfaces.
Note: Hard facing (equal to CoCr-A) includes such trademarked materials as Stellite 6,
Stoody 6, and Wallex 6.
b) Bonnet and cover bolting material for valves NPS 3 and larger will be specified and shall be of
the same material specification as the bolting used for connecting piping.
2) [S] Solid high nickel alloy valves shall not have any components made from cast material.
3) [S] Bar stock shall not be used to manufacturer solid high nickel alloy valves larger than NPS 1.
4) [*][R] The selection of the correct elastomer and or non-metallic seal material must be done with
consideration of ALL the design conditions (pressure, temperature, chemical environment, etc.)
under which the valve will operate and shall be based on the selection criteria as defined in PG-
PDS 29-01-37. Supplier will include selection details in his proposal to the Purchaser for approval
by the Owner's Engineer prior to award.

4. DESIGN
1) [R] Valve design shall meet the requirements of ASME B16.34 and the following product
specification standards as applicable:

a) Check Valves—API STD 594

b) Plug Valves—API STD 599

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 PG-PDS 03-12-09 General Requirements for Valves Sep 2009

c) Gate Valves—API STD 600, API STD 603

d) Forged Gate Valves—API STD 602
e) Ball Valves—API STD 608, API SPEC 6D
f) Butterfly Valves—API STD 609
2) [*] [R] All pressure containing welds, and welds made on pressure containing components, shall
meet the requirements of PG-PDS 29-01-01, PG-PDS 29-03-02, and PG-PDS 29-03-03. The
Supplier may exempt hardfacing welds on components that are not part of the pressure boundary
if the Supplier can demonstrate weld adequacy by an appropriate mockup in his proposal to the
Purchaser for approval by the Owner's Engineer.
3) [S] Valve stems and check valve/butterfly valve shafts shall be blow-out 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.
4) [*][O], [M] The Supplier shall submit counterweight designs for check valves to the Purchaser in
his proposal for approval by the Owner's Engineer. Drawings for check valves with
counterweights shall clearly indicate whether the counterweights are provided to assist quick
closure or to provide damping. They shall also indicate the required counterweight location and
the weight and center of gravity of all components attached to the hinge pin.
5) [*] [O], [R] When horizontal stem orientation is required or specified for gate valves NPS 10 or
greater in horizontal lines, valve internals shall be designed to avoid wedge jamming. The
Supplier shall submit designs to the Purchaser in his proposal for approval by the Owner's
Engineer.
6) [S] [R] All valves designed with elastomer seals and or O-rings shall be qualified for the service
and design conditions (pressure/temperature range) for each type of valve construction offered by
the manufacturer. Each seal material and configuration (seal groove size versus seal shape and
groove fill) shall be evaluated for the specified duty (refer to PG-PDS 29-01-37 for appropriate
elastomer selection).
a) [*] The valve "type test" using the performance method and qualification range as per API
SPEC 6A Annex F is considered a basis to qualify each type of valve construction (including
ball and globe types). A modified API SPEC 6A Annex F performance test may be
acceptable, provided the Supplier submits the proposed test procedure in his proposal to the
Purchaser for approval by the Owners’s Engineer..
b) Valves shall be "type" tested if any of the following applies:
i) Manufacturer has made changes to the qualified design of the elastomer seal
configuration and or material (i.e. change in seat, stem or seal design configuration,
materials, design parameters, etc)
ii) The manufacturer has no previous qualified project experience with the particular seal
material and or configuration.
7) Actuators for on/off valves shall be selected and inspected per requirements of GP 15-09-03

4.1. Additional Requirements for Valves Equipped with

Chainwheels
1) [R] When chainwheels are specified, they shall be of the direct mounted adjustable sprocket rim
type. Clamp-on type chainwheels for valves greater than NPS 2 (50 mm) are not permitted.
2) [S] Chainwheels shall include a supplementary retention device such as a safety chain or cable.
Chain guides shall be included.
3) [S] Valve chainwheels shall not be made with cast iron components.

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5. ADDITIONAL REQUIREMENTS FOR LOW ALLOY VALVES IN HYDROGEN

SERVICE AND AUSTENITIC STAINLESS STEEL VALVES IN HIGH
PRESSURE SERVICE
1) [R] When hydrogen service is specified, low alloy valve castings (P-numbers 3, 4, and 5
materials) shall be magnetic particle and radiographically examined per PG-PDS 18-03-04.
2) [R] Austenitic stainless steel valve castings, with a rating of Class 1500 or 2500 shall be liquid
penetrant and radiographically examined per PG-PDS 18-03-04.

6. ADDITIONAL REQUIREMENTS FOR VALVES

6.1. In Wet H2S Service

1) [R] Postweld heat treatment (PWHT) is required for all carbon and ferritic alloy steel pressure-
containing components that are welded and/or weld repaired, except as specifically exempted in
Items a through c below. The PWHT procedure outlined in ASME B31.3, Paragraph 331.1 shall
be followed; however, the exceptions provided in Table 331.1.1, based on wall thickness, are not
permitted. The minimum PWHT temperature shall be per ASME B31.3 for the material used, but
not less than 620°C (1150°F).
The specific types of welds listed in Items a through c below are exempt from the special PWHT
requirements of this Section. However, this does not exempt these welds from PWHT which may
be required for other reasons.
a) Multipass girth welds, welded from the outside surface only.
b) External attachment welds, when the weld is not in contact with wet H2S.
c) Multipass seal and socket welds.
2) [R] Hardness of the base metal of the body, bonnet, cap, stem, closure components (excluding
locally hardened seating surfaces), and butterfly valve seat retainer ring, and of the weld metal
and related heat affected zone (HAZ) of any pressure retaining welds, shall not exceed the limits
given by Table 1
3) [R] The hardness test for the HAZ shall be made with the ball centered in the HAZ to represent a
composite of weld metal, HAZ and base metal. Tests on valve stems, including any integral
components to stems, shall be made with a Rockwell Testing Machine using the "C" hardness
scale.

Table 1: Hardness Requirements for Valves in Wet H2S Service

Hardness (5)
Material/P-Number
Other Than Stem Stem

P-1 (2)(3) 200 HB (1) Not Applicable

(1)
P-3, P-4, P-10, P-10 A&B, P-11, P11A 225 HB Not Applicable
(1)
P-5 235 HB Not Applicable
(1)(4)
P-6, P-7 235 HB 22 HRC
(1)
Inconel, precipitation hardened 310 HB 33 HRC
17-4PH, double precipitation hardened Not Applicable 33 HRC
Notes:

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Hardness (5)
Material/P-Number
Other Than Stem Stem

(1) For base metal use the value shown or the value given in the specific ASTM
standard, whichever is lower.
(2) No testing is required on the HAZ.
(3) Testing is only required on the base metal if hot forming (forging) followed by
water quenching is used.
(4) Plugs or balls of 13 Cr material shall have a maximum Brinnell hardness of 225.
(5) Except where noted, tests shall be made with a Brinell Testing Machine. A
portable hardness tester may be used providing the diameter of the indentation
ball is not smaller than 7 mm and not larger than 10 mm, and the hardness of the
reference bar is within ±12.5 percent of the maximum hardness required for the
specific material.

6.1.1. Verification of Hardness Values

[R] Unless otherwise specified, examinations shall be made in the presence of the Inspector to verify
compliance with the specified hardness requirements. The minimum number of hardness checks
shall be specified in Table 2.

Table 2: Minimum Hardness Examinations for Valves in Wet H2S Service

Minimum Number of Hardness Tests

Valve Components Material Base Metal Weld Metal HAZ

P-1 Minimum 5 percent Note(1) None

(minimum of one
P-3, P-4, P-5, P-6 valve) of each size,
Shell (4) P-7, P-10, P-10 10 percent of Welds
style and material
A&B, per order
P-11, P-11A
Closure Component All Minimum of one valve of each style and material per order
(2)(3)
and Trim, including
Stem
Notes:
(1) Test 10 percent of the welds made by the:
a. SMAW process using ferritic filler metal other than Class E60-70XX per ANSI/AWS A5.1.
b. GTAW (TIG), GMAW (MIG or MAG) processes-using filler metal other than ER70S-2 through
ER70S-5 per ANSI/AWS A5.18.
c. FCAW process using filler metal other than E7XT-1,-5,-9,-12 with CO2 or E7XT-1M,-5M,-9M,-
12M with either CO2 or Ar/ CO2 mixture.
d. [*] If Supplier proposes SAW (submerged arc) process using filler-metal other than a
combination ELX or EMX wires per ANSI/AWS A5.17 and neutral flux Supplier shall submit
details to Purchaser in his proposal for approval by Owner's Engineer.
(2) Supplier may verify hardness by testing trim-components other than those in the order, which have
been manufactured (fabrication and thermal treatment) the same as those being furnished.
(3) Supplier certification of materials is required.

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(4) Includes body, bonnet, cap, butterfly valve seat retainer ring.

6.2. In Methanol Service

Seal Selection shall be consistent with PG-PDS 29-01-37

7. ADDITIONAL REQUIREMENTS FOR COMPACT VALVES REQUIRING

POSTWELD HEAT TREATMENT
1) [R] If socket welding valves with welded-in pipe stubs requiring PWHT are specified:
a) [*] Pipe stubs shall be 150 mm long, unless otherwise specified.
b) Valve body and stub assembly shall be heat treated prior to finish machining of the valves.
2) [R] If gusset stub (or pad) attachments to valves are specified:
a) Dimensions and configuration of the gusset stubs shall be as illustrated in Figure 1.
b) Gusset stub (or pad) location shall be on the upstream or downstream side of globe valves,
as specified.

Figure 1: Gusset Stub Attachments

1/2 in. (13 mm)

3/16 in. (5 mm)

STUBS FOR
TWO PLANE
1-1/2 in.

(38 mm)

1 GUSSETING
1

2 in. NPS 2 in.

(50 mm) (50 mm)

COMPACT BODY VALVE EXTENDED BODY VALVE

NOTE:
(1) Gusset stub dimensions are minimum.

c) PWHT shall be done after welding the attachments to the valve body.
d) Gusset stub material shall be of the same nominal chemistry as the valve body, except that
carbon steel may be used for P-1, P-3, P-4, and P-5 materials.
e) Filler metal shall match the chemistry of the valve body as closely as possible.
f) Gussets shall be welded by valve manufacturers where seat integrity can be assured. No
welding to valve bodies on site is permitted.

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8. INSPECTION AND TESTING

1) [R] All valves shall meet the inspection and testing requirements of ASME B16.34 as appropriate
for the valve's method of manufacture (i.e., cast, forged, welded, etc.) plus the additional
requirements listed in this Section, Section 5 and PG-PDS 18-03-04 as applicable.
2) All prototype designs shall be "type" tested for performance verification in accordance with
Section 4. A valve shall be considered a prototype if any of the following apply:
a) Manufacturer has made changes to the qualified design.
b) The manufacturing facility has no previous experience with the particular valve model.
3) [R] Quarter-turn valves shall be tested with the final gear operator installed.
4) [R] Seat tests (low and/or high pressure) shall be conducted with air/nitrogen and discharge
slightly below water to facilitate determination of leakage rates.
5) [R] All valves intended for Type B or C isolation services (as defined in PG-PDS 03-01-01, Table
5), shall be high pressure closure tested per API STD 598. The definition of "double block and
bleed" as referenced within API STD 598, shall be as defined in API SPEC 6D. Leakage shall be
measured through the open bleed as specified in the seat test requirements in previous item (4).
6) [R] To verify the capability of the metal seat to provide positive shutoff for soft sealed gate valves,
a minimum of 5 percent (minimum of one valve) of each size in the order, shall be High Pressure
Closure and Low Pressure Closure tested per API STD 598 without the soft seal in place. The
test valve shall be stroked open and shut at least one time prior to these tests. Leakage shall not
exceed rates specified for metal seated valves.
7) [O] Closure torque during test. For handwheel and gear operated (manual) valves, closure
torque shall not be greater than the limitations specified in PG-PDS 03-01-01.
8) Positive Material Identification (PMI) of alloy and stainless steel valves shall be per PG-PDS 29-
01-01.
9) [R] Valve closure tests shall be per API STD 598 except that all prototype designs shall be high-
and low-pressure closure tested.
10) [R] Valves required to operate (i.e. stroked or cycled) at a process temperature below −29°C
(−20°F) shall be subjected to low temperature [−46°C (−50°F)] or cryogenic [−196°C (−320°F)]
testing in accordance with PG-PDS 03-99-03.

9. PREPARATION FOR SHIPMENT

9.1. General Requirements

1) [M] 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.
2) [M] Valves shall be crated for shipment to protect against internal and external damage including
operating mechanisms.

9.2. Protective Coatings

1) [M] The painting of unmachined exterior surfaces of valves shall be per PG-PDS 29-02-03.

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2) [M] 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 twelve months exposed to a
normal industrial environment.
b) To be removable with mineral spirits or any Stoddard solvent.

9.3. Valve Protection

1) [M] 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.
2) [M] Valves with threaded or socket welding ends shall have the ends protected with metal, wood,
or plastic caps or plugs.
3) [M] 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.

9.4. Identification and Labeling

1) [R] Valves which have passed the API STD 598 high pressure closure test with the body bleed
open shall be permanently marked or tagged "Bleed-Tested."
2) [R] Manufacturer's standard soft-sealed valves shall be permanently marked or tagged with the
valve temperature pressure rating at 38 C 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.
3) [O] Valves with a preferred flow direction shall have the direction of flow cast or steel stamped on
the valve body.
4) [O] When check valves are provided with a drilled orifice hole in the plate, the size of the orifice
shall be stamped on the body with a low stress stamp.
5) [S] All soft-seated quarter-turn valves that have passed the "fire-tested" requirements of API STD
607 shall be tagged "fire-tested design."
6) [M] Soft-sealed valves with welding ends, socket welding ends, or threaded ends requiring seal
welds, shall be provided with a warning tag if removal of all soft-sealing material from valve prior
to welding is required.

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ATTACHMENT: PURPOSE CODES DEFINITIONS

Code Description

* An asterisk indicates that additional information from the Owner’s Engineer is required, or
approval by the Owner’s Engineer is required.
C Assigned to paragraphs containing specifications whose primary purpose is reduced costs.
Reduced cost in this context refers to initial investment cost and does not include Life-Cycle
cost considerations. Life-Cycle cost considerations are captured under reliability,
maintainability, or operability purpose codes.
E Assigned to paragraphs containing specifications whose primary purpose is driven by
environmental considerations. Environmental considerations typically include specifications
intended to protect against emissions/leakage to the air, water, and/or soil. Deviations from the
specifications contained in such paragraphs require formal review and approval according to
local environmental policy.
I Assigned to paragraphs that provide only clarifying information such as Scope statements,
definitions of terms, etc.
M Assigned to paragraphs containing specifications whose primary purpose is to provide for
maintainability of equipment or systems. Maintainability provisions are those that facilitate the
performance of maintenance on equipment/systems either during downtimes or during on-
stream operations.
O Assigned to paragraphs containing specifications whose primary purpose is to assure
operability of equipment or systems. Operability is the ability of the equipment/system to
perform satisfactorily even though conditions are off-design, such as during startups, process
swings, subcomponent malfunction, etc.
R Assigned to paragraphs containing specifications whose primary purpose is to improve or
assure the reliability of equipment or systems. Reliability is a measure of the ability of
equipment/systems to operate without malfunction or failure between planned maintenance
interventions.
S Assigned to paragraphs containing specifications whose primary purpose is avoidance of
personnel or operational safety incidents. Any deviation from the specifications contained in
such designated paragraphs requires formal review and approval according to local safety
policy.
Personnel Safety: Refers to the avoidance of recordable personnel injuries; i.e., burns, cuts,
abrasions, inhalation, or exposure to dangerous substances, etc., that
could result in medical treatment, restricted work, lost-time incidents, or
fatalities.
Operational Refers to the prevention and control of process releases, fires,
Safety: explosions, etc.

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RECORD OF CHANGE

Version 1.0.0 Date:

Sept 30 2009

Location Action Description

Section 8, Modification Valve inspection requirements to ASME B16.34 added.
Item (1)
Section 8, Modification Expanded definition of prototype designs, referenced Section 4
Item (2)
Section 8, New Added reference for PG-PDS 29-01-01
Item (8)
Section 8, Modification Modified reference to API STD 598
Item (9)
Section 8, New Added reference PG-PDS 03-99-03
Item (10)

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