-
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
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.
This page was intentionally left blank
-
Petroleum Development Oman LLC
Revision: 0 Effective: July-13
Page 4 Valves Technical Specification 15/07/13
The controlled version of this CMF Document resides online in
Livelink. Printed copies are UNCONTROLLED.
ii Revision History
The following is a brief summary of the 4 most recent revisions
to this document. Details of all revisions prior to these are held
on file by the issuing department.
Version No. Date Author Scope / Remarks
0 15 July 2013 Mahesh Manjakuppam Srinivasan First Issue
iii Related Business Processes
Code Business Process (EPBM 4.0)
EP 64 Design, Construct, 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.
-
Petroleum Development Oman LLC
Revision: 0 Effective: July-13
Page 5 Valves Technical Specification 15/07/13
The controlled version of this CMF Document resides online in
Livelink. Printed copies are UNCONTROLLED.
TABLE OF CONTENTS
i Document Authorisation
.........................................................................................................
3
ii Revision History
.....................................................................................................................
4
iii Related Business Processes
.................................................................................................
4
iv Related Corporate Management Frame Work (CMF) Documents
........................................ 4
1 Introduction
............................................................................................................................
6
1.1 Purpose
............................................................................................................................
6
1.2 Changes to the Specification
............................................................................................
6
1.3 Exceptions
........................................................................................................................
6
1.4 Reference Documents
.....................................................................................................
6
2 General requirements:
...........................................................................................................
7
2.1 Design and Construction
..................................................................................................
7
2.2 Seat and Sealing
..............................................................................................................
7
2.3 Valve Operator
.................................................................................................................
8
2.4 Valve lifting and supporting provision
...............................................................................
9
2.5 Weld overlay
.....................................................................................................................
9
2.6 Vent / Drain Connection
...................................................................................................
9
2.7 Painting and Coating
........................................................................................................
9
2.8 Sub Contracting
................................................................................................................
9
3 Special Services
...................................................................................................................
10
3.1 ESD/IPF/HIPPS Ball Valves
...........................................................................................
10
4 Inspection and Testing
.........................................................................................................
11
4.1 Additional Inspection / Testing Requirements:
...............................................................
11
4.2 TAT requirements:
.........................................................................................................
11
5 Appendix A - Glossary of Definitions, Terms and Abbreviations
......................................... 12
6 Appendix B Typical Lip seal Arrangements
......................................................................
13
7 Appendix C Typical Arrangements of CRA sleeve weld detail in
drain / vent port of Weld overlay valves:
.............................................................................................................................
15
8 Appendix D Typical arrangements of Vent and Drain with
threaded plug: ........................ 16
9 Appendix E User Feedback Page
........................................................................................
17
-
Petroleum Development Oman LLC
Revision: 0 Effective: July-13
Page 6 Valves Technical Specification 15/07/13
The controlled version of this CMF Document resides online in
Livelink. Printed copies are UNCONTROLLED.
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, MESC specification, SHELL SPE and technical
requisition. The purpose of this specification is to upgrade the
valve integrity in terms of reliability and safety.
1.2 Changes to the Specification This specification shall not be
changed without approval from the Custodian, CFDH Mechanical
(Static), who owns this specification. If you think any part of
this specification is not correct, write your comments on a copy of
the User Comments Form. The form is included as the last page of
this specification. Send the copy with your comments and personal
details to DCS after discussion with (CFDH Static).
1.3 Exceptions Any proposed exceptions or variations to this
specification shall be submitted to the Company or its
representative for approval prior to manufacture. In case of any
conflict between the requisition/datasheet and this specification,
vendor shall seek approval from the Company. Any work completed
with unauthorised modifications may be rejected by the Company. Any
subsequent re-work shall be in accordance with this specification
and shall be to the Manufacturers/Suppliers account.
1.4 Reference Documents
API 6D Specification for pipeline valve
ISO 14313 Petroleum and Natural Gas industries - Pipeline
transportation system Petroleum and Natural Gas industries-Pipeline
valves
API 6A Specification for Wellhead Equipment
ASME B16.34 Valves Flanged, Threaded and welding end
ASME B16.10 Face to Face and End to End Dimensions of valves
DEP 30.00.60.13-Gen Human Factors Engineering-Valves.
SPE77/313 Valves with CRA Cladding
SPE77/312 Fugitive Emission Production Testing
SPE77/302 Valves-General requirements
SP1246 Specification for Painting and Coating of Oil and Gas
Production Facilities
SP1173 Welding of Metals
-
Petroleum Development Oman LLC
Revision: 0 Effective: July-13
Page 7 Valves Technical Specification 15/07/13
The controlled version of this CMF Document resides online in
Livelink. Printed copies are UNCONTROLLED.
2 General requirements:
2.1 Design and Construction Vendor shall have performed required
design calculations for all the valves for which they are approved
in the PDO PGSC list. 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
16.34.
For carbon steel valve, minimum 3 mm corrosion allowance shall
be considered in the design unless other wise specified in the
requisition. The cast body of valve shall not have any sharp
contour which may see crack, shrinkage and blow hole as the molten
materials may not flow smoothly to the sharp corner of the valve
during casting.
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.
2.2 Seat and Sealing
If the seal material specified in the requisition as
thermoplastic, it shall be of Lip seal type with Eligiloy 718
spring material. Chevron pack may be acceptable for stem sealing.
If the seal material is specified as elstomeric materials it shall
be AED (Anti Explosive decompression) type. Vendor shall have the
material specification and EN10204 2.1 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.
Refer Annexure-B for the typical arrangement of lip seal
arrangement in the ball valve. Ball valve Seat ring shall have
primary lip seal with a fire safe graphite ring. The Valve rated
API 10000# and above shall be metal seated and zero seat leakage
across the valve as per API 6A. The hard facing of metal seated
high pressure ball valves (ASME 1500 # and higher) shall be with
Tungsten carbide or Chromium carbide. The temperature limit for the
tungsten carbide is max. 200 DegC, for higher temperature Chromium
carbide shall be used. The requirements of hard face coating of
tungsten carbide (TC) or chromium carbide shall be: - Thickness of
minimum 400 microns after grinding and polishing. - Tensile bond
strength > 10,000 psi - Min. Hardness 1050HV.
For CS ball valve with trim material of DSS or SDSS or Alloy 825
construction, the seal pocket of static/dynamic lip seal or chevron
seal shall be with Alloy 625 weld overlay. If vendor is unable to
carry out weld overlay on the seal pocket areas in the smaller size
of valve, the valve body/bonnet shall be supplied with the same
material of trim. 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. No O ring
is allowed in the Body /bonnet joint
-
Petroleum Development Oman LLC
Revision: 0 Effective: July-13
Page 8 Valves Technical Specification 15/07/13
The controlled version of this CMF Document resides online in
Livelink. Printed copies are UNCONTROLLED.
2.3 Valve Operator
Manually operated valves shall be operated by a lever, wrench or
hand wheel. The direction of operation shall be clockwise for
closing the valves. 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), as measured on the rim of the hand wheel or
the end of the lever or wrench. For hand wheels or levers between
50 mm (2 in) and 125 mm (5 in) in diameter or length(i.e. intended
for one-handed operation) the maximum force shall not exceed 66 N
(15 lbf),as measured on the rim of the hand wheel or end of lever
or wrench. 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. Gear Operator shall be provided for manual valves
in accordance with the following table:
ASME
Class
Valve Type
Gate Globe / Plug Ball Butterfly
150 DN 350
(NPS 14) and larger
DN 250 (NPS 10) and larger
DN 150 (NPS 6) and larger
DN 200 (NPS 8) and larger
300 DN 300 (NPS
12) and larger
DN 200 (NPS 8) and larger
DN 100 (NPS 4) and larger
DN 200 (NPS 8) and larger
600 DN 150 (NPS 6)
and larger DN 200 (NPS 8)
and larger DN 100 (NPS 4)
and larger
900 DN 100 (NPS 4)
and larger DN 150 (NPS 6)
and larger DN 80 (NPS 3)
and larger
1500 DN 100 (NPS 4)
and larger DN 80 (NPS 3)
and larger DN 80 (NPS 3)
and larger
=>2500 DN 80 (NPS 3)
and larger DN 80 (NPS 3)
and larger DN 80 (NPS 3)
and larger
NOTES: 1. 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...
2. Manufacturers can provide gear operators for lesser size also
as per their standards...
Table 1.0
Valve that requires more than 100 turns to go from fully open to
fully closed should be equipped with actuators (hydraulic, electric
or pneumatic) or mobile operators upon approved by company. The
gear box output torque rating shall be at least 1.5 times the
maximum required operations torque of the valve. Gear operator
shall be heavy duty, totally enclosed, grease-filled, self-locking
type, and dust and weather proof to IP 55, suitable for outdoor
installation. [Where specified, the gear enclosure shall be water
proof/splash proof to IP 65.] The gear operator shall be adjustable
at 45 degree increments in the field
-
Petroleum Development Oman LLC
Revision: 0 Effective: July-13
Page 9 Valves Technical Specification 15/07/13
The controlled version of this CMF Document resides online in
Livelink. Printed copies are UNCONTROLLED.
2.4 Valve lifting and supporting provision
Valves of sizes 8NPS (200NB) and above or 250Kg and heavier
shall be equipped with lifting lugs. Tapped holes and eye bolts
shall not be used for lifting. Lifting lugs position shall allow
for safe handling of valve with Gear box or actuator. 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 support height shall be as minimum as possible.
2.5 Weld overlay
For top entry ball valves, the internal CRA weld overlay in the
body /bonnet is applicable only for size 8 inch and above. The 6
inch and smaller valve size shall be of solid CRA material.
If stellite is specified as hard facing, it shall be weld
overlay and minimum finished thickness of welded-on hard facing
material shall be 3.0 mm, unless otherwise specified...
The weld overlay of valve body vent /drain port shall be similar
to the arrangement shown
in the Annexure-C.
2.6 Vent / Drain Connection
The plug material shall be same as the trim material. If the
drain port is at the bottom most portion of the body, the plug
shall be extended to full length of port so that no
accumulation of solid particles / debris is entrapped in the
drain port. Refer Annexure-D
No seal welding should be performed on the plug after shop or
field Hydro testing. The vent /drain plug shall have threaded cover
cap as shown in the sketch.
The minimum size of flanged vent and drain port shall be one (1)
inch. The flanged connections shall be butt welded to the body or
pad type flanged. No socket welded pipe with flange connection is
permitted.
2.7 Painting and Coating
The painting and coating of valve body shall be as per SP-1246.
The Alloy 625 /825 / Alloy28 body does not require any coating /
painting.
The valve bolting (B7 / B7M) shall be with ENP + PTFE top coated
for the design temperature less than 200 Deg C.
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.
2.8 Sub Contracting
All valves are deemed to be machined, assembled and tested at
the company approved premises. Any deviation to this, requires a
prior approval from the company, which must be obtained at the time
of bidding stage.
If any works are outsourced after company approval, the
manufacturer shall maintain full QA/QC control over sub contracting
activities.
The sub contractor of Weld overlay works shall be approved by
company prior to commence any weld over lay works.
-
Petroleum Development Oman LLC
Revision: 0 Effective: July-13
Page 10 Valves Technical Specification 15/07/13
The controlled version of this CMF Document resides online in
Livelink. Printed copies are UNCONTROLLED.
3 Special Services
3.1 ESD/IPF/HIPPS Ball Valves
The valve shall be of trunnion type with metal seat arrangement
and minimum size of 2 inch. The upstream seat shall be with single
piston effect and down stream seat with double piston effect. 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. However, the valve shall be suitable for bi-directional
isolation..
The Seat ring shall have primary lip seals (2 nos.) with a fire
safe graphite ring. The stem side shall have minimum two (2)
primary lip seals or U or V shaped packing with fire safe secondary
seals. The grease fitting shall be provided between primary and
secondary seal on the stem side with two in- built check valves.
The Grease thread fitting shall be anti blow out plug type and with
two (seals). The material of grease fitting shall be same of valve
trim material.
No seat sealant injection shall be provided for these
valves.
-
Petroleum Development Oman LLC
Revision: 0 Effective: July-13
Page 11 Valves Technical Specification 15/07/13
The controlled version of this CMF Document resides online in
Livelink. Printed copies are UNCONTROLLED.
4 Inspection and Testing
4.1 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. However,
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. In the event of failure, 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.
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.
All but end valves shall be considered as IC-IV of SPE
77/302.
The API 6A rated valves used for gas service shall be minimum
comply with PSL3G and PR2 requirements.
The ITP shall include minimum the following activities:
- Materials inspections/ testing( body/bonnets/closure
members/stem/bolts/nuts/seals) - Soft seat material certificates. -
Visual inspections(rough / machined ) - WPS /PQR for the weld
overlay - Required NDEs for the valve and weld overlay. - Test and
inspection of hard facing including sample bond /hardness test. -
All required testing on assembled valves including valve stem
torque tests, cavity relief
tests,, - Inspection /testing of Painting (Visual/thickness/
adhesive). - Tagging and marking - Visual inspection prior to
packing(internal/external/ fittings on the valve body) -
Preservation and Packing.
4.2 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. If the waiver to TAT is required,
vendor shall fully comply with the following requirements in
addition to MESC, SPE 77/302 and section 4.1 of this
specification.
- 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,
whichever is stringent.
- The soft seal material (Lip seals) material shall be from
Saint-Gobain and provide 2.2 material certificates for TPI witness
prior to assemble the valves.
- All valves shall undergo production FE (Fugitive Emission)
testing. - The final inspection and testing including visual
inspections prior to packing shall be in
accordance with ISO 10474 3.1C certificate or EN10204 3.2.
TPI shall be involved in all inspection / testing which shall be
at vendor cost and vendor shall get company approved on TPI.
-
Petroleum Development Oman LLC
Revision: 0 Effective: July-13
Page 12 Valves Technical Specification 15/07/13
The controlled version of this CMF Document resides online in
Livelink. Printed copies are UNCONTROLLED.
5 Appendix A - Glossary of Definitions, Terms and
Abbreviations
A.1 Terms and Definitions
Companyr
Buyer
Petroleum Development Oman LLC. The Company may also include an
agent or consultant authorised to act for and on behalf of the
Company. EPC/EMC/ODC contractors.
Corporate Functional
Discipline Head
The person within the Company responsible for the discipline to
which the standard belongs
Manufacturer/Supplier
The party which manufactures or supplies equipment and services
to perform the duties specified by the Company.
User
The Company Manufacturer/Supplier or Consultant that uses this
document.
shall Indicates a requirement.
should Indicates a recommendation.
may Indicates a possible course of action.
Fire tested design A design subjected successfully to fire
testing
Fire safe design A design that by the nature of its features and
materials is capable of passing a fire test
A.2 Abbreviations
ASME American Society of Mechanical Engineers
BCD Business Control Document
CFDH Corporate Functional Discipline Head
DCS Document Control Section
NDE Non Destructive Examinations
IPF Instrument Protective function
HIPPS High Integrity Pressure protective system
ENP Electroless Nickel Plating
ESD Emergency Shut Down
MPI Magnetic Particle Inspection
RED Requisition for Engineering Documents
-
Petroleum Development Oman LLC
Revision: 0 Effective: July-13
Page 13 Valves Technical Specification 15/07/13
The controlled version of this CMF Document resides online in
Livelink. Printed copies are UNCONTROLLED.
6 Appendix B Typical Lip seal Arrangements
Typical Ball Valve Body/Bonnet arrangement with Lip seal
Typical Stem side seal Arrangement with Lip seals
-
Petroleum Development Oman LLC
Revision: 0 Effective: July-13
Page 14 Valves Technical Specification 15/07/13
The controlled version of this CMF Document resides online in
Livelink. Printed copies are UNCONTROLLED.
Typical Arrangement of Lip seal on the ball valve seat ring
Note : 1.The arrangement shown in the above sketch is just
representative only. Vendor should provide
as per their approved standards meeting all the required
specifications.
2. The Lip seals provided on the CS body / bonnet, the seal
pocket shall be weld overlay as per
section 2.2
-
Petroleum Development Oman LLC
Revision: 0 Effective: July-13
Page 15 Valves Technical Specification 15/07/13
The controlled version of this CMF Document resides online in
Livelink. Printed copies are UNCONTROLLED.
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.
2: The sleeve shall be with Anti blow out arrangement.
3:.Drilling of port shall be done after completion of internal
body weld overlay.
4: The sleeve should be cold fitted.
-
Petroleum Development Oman LLC
Revision: 0 Effective: July-13
Page 16 Valves Technical Specification 15/07/13
The controlled version of this CMF Document resides online in
Livelink. Printed copies are UNCONTROLLED.
8 Appendix D Typical arrangements of Vent and Drain with
threaded plug:
-
Petroleum Development Oman LLC
Revision: 0 Effective: July-13
Page 17 Valves Technical Specification 15/07/13
The controlled version of this CMF Document resides online in
Livelink. Printed copies are UNCONTROLLED.
9 Appendix E User Feedback Page
SP-2154 VALVES TECHNICAL SPECIFICATION USER FEEDBACK FORM
Any user who identifies an inaccuracy, error or ambiguity is
requested to notify the custodian so that appropriate action can be
taken. The user is requested to return this page fully completed,
indicating precisely the amendment(s) recommended.
Name:
Ref ID Date:
Page Ref: Brief Description of Change Required and Reasons
To: UEP/10S - Mahesh Manjakuppam Srinivasan
Custodian of Document Date: