Technical Supply Conditions For Valves

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TECHNICAL SUPPLY CONDITIONS
FOR VALVES
PROJECT DOCUMENT NO.

The drawing, design and details given on this format are the property of ESSAR ENGINEERING CENTRE. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied,
DETAILS OF REVISION REV NO
25/04/07 ISSUED FOR REVIEW 00

04/05/07 ISSUED FOR DESIGN 01
12/07/07 RE-ISSUED FOR DESIGN 02
03/09/07 ISSUED IN REVISED FORMAT 04
19/07/08 REVISED AS PER COMMENTS 05
exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.
TECHNICAL SUPPLY CONDITIONS FOR EESL DOCUMENT NO

GEN-004-R1
VALVES EECS-20-102-020-07
ESSAR ENGINEERING SERVICES LTD ,
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Contents
1. Scope…………… ........................................................................................................ 4
2. Conflicts and Deviations ............................................................................................. 4
3. Reference Documents ................................................................................................ 4
4. Exceptions to Specified Requirements ....................................................................... 7
5. General Requirements ................................................................................................ 7
6. Design…. .................................................................................................................... 8
7. Inspection and Testing .............................................................................................. 12
8. Cleaning .................................................................................................................. 26
9. Painting .................................................................................................................. 26
10. Documentation .......................................................................................................... 26
11. Preparation For Shipment ....................................................................................... 27

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1. SCOPE
1.1. This document specifies the minimum requirements governing the supply of all valves, whether
supplied as bulk materials or as part of an equipment package unit. It forms an integral part of any
Enquiry, Material Requisition or Purchase Order package for piping components and shall be read in
conjunction with the documentation referenced therein.
2. CONFLICTS AND DEVIATIONS

2.1. Any conflict between any requirements specified in this document and the requirements of any other
relevant referenced document shall be resolved in the following order of Preference:
• The Commodity Code Description (or item description) in the Enquiry, Material Requisition or
Purchase Order.
• This Specification.
• Other Project Specifications.
• Referenced Codes and Standards.
3. REFERENCE DOCUMENTS
3.1. All valves & accessories shall conform to the requirements of ASME B31.3 and the relevant referenced
Codes, Standards and Specifications, listed below.
American Society of Mechanical Engineers (ASME)
B1.1 Unified Inch Screw Threads (UN and UNR Thread Form).
B1.20.1 Pipe Threads, General Purpose (Inch).
B 16.5 Pipe Flanges and Flanged Fittings.
B16.9 Factory Made Wrought Butt-Welding Fittings.
B16.11 Forged Fittings, Socket Welding and Threaded.
B16.14 Ferrous Pipe Plugs, Bushings, and Lock Nuts with Pipe
Threads.
B16.25 Butt-Welding Ends.
B 16.34 Valves-Flanged, Threaded and Welding End.
B16.10 Face to Face and End to End Dimension of valves.
B31.1 Power Piping.
B31.3 Process Piping.

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The drawing, design and details given on this format are the property of ESSAR ENGINEERING CENTRE. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, B36.10 Welded and Seamless Wrought Steel Pipes.
B36.19 Stainless Steel Pipes.
B46.1 Surface Textures.
American Petroleum Institute (API)

5L Specification for Line Pipe
6D Pipeline Valves.
594 Check Valves: Wafer, Wafer-Lug and Double Flanged Type
598 Valve Inspection and Testing
599 Metal Plug Valves- Flanged and Welding Ends
600 Bolted Bonnet Steel Gate Valves for Petroleum and Natural Gas Industries.
602 Compact Steel Gate Valves- Flanged, Threaded, Welding and Butt
Welding Ends.
603 Corrosion Resistant, Bolted Bonnet Gate Valves- Flanged and Butt
Welding Ends.
607 Fire Test for Soft-Seated Quarter-Turn Valves
608 Metal Ball Valves- Flanged, Threaded and Welding End.
609 Butterfly Valves: Double Flanged Lug And Wafer Type.
Manufacturers Standardisation Society (MSS)

SP-6 Standard Finishes for Contact Faces of Pipe Flanges and Connecting-End
Flanges of Valves and Fittings
SP-9 Spot Facing for Bronze, Iron and Steel Flanges
SP-25 Standard Marking System for Valves, Flange, Fittings, Flanges and Unions
SP-42 Class 150 (PN 20) Corrosion Resistant Gate, Globe, Angle and Check
Valves with Flanged and Butt Weld Ends
SP-43 Wrought Stainless Steel Butt-Welding Fittings.
SP-54 Quality Standard for Steel Castings- Radiographic Inspection Method for
Valves, Flanges, Fittings and Other Piping Components
SP-55 Quality Standard for Steel Castings for Valves, Flanges and Fittings and
Other Piping Components, Visual Method for Evaluation of Surface
Irregularities

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The drawing, design and details given on this format are the property of ESSAR ENGINEERING CENTRE. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, SP-60 Connecting Flange Joint Between Tapping Sleeves and Tapping
SP-61 Pressure Testing of Steel Valves
SP-67 Butterfly Valves
SP-70 Cast Iron Gate Valves, Flanged and Threaded Ends
SP-71 Gray Iron Swing Check Valves, Flanged and Threaded Ends
SP-72 Ball Valves With Flanged or Butt-Welding Ends for General Service
SP-78 Cast Iron Plug Valves, Flanged and Threaded Ends
SP-80 Bronze Gate, Globe, Angle and Check Valves
SP-82 Valves Pressure Testing Methods
SP-84 Steel Valves Socket Welding and Threaded Ends
SP-86 Metric Data in Standards for Valves, Flanges and Fittings
SP-95 Swaged Nipples and Bull Plugs
SP-97 Forged Integrally Reinforced Branch Outlet Fittings - Socket Welding,
threaded and Butt-Welding Ends
American Society for Testing Materials (ASTM)

D2996 Standard Specification for Filament Wound Fibre Glass (Glass Fibre
reinforced Thermosetting Resin) Pipe.
International Organisation for Standardisation (ISO)

8501-1 Preparation of Steel Substrates Before Application of Paints and related
Products - Visual assessment of surface cleanliness.
.
Deutsches Institut für Normung (DIN)
DIN 50 049 Metallic Products- Type of Inspection Documents.
Indian Standards and Regulations (IS)

Indian Boiler Code for Steam and Feed Water Regulations
IS1239 Part 1 Specification For Steel Tubes, Tubulars and other Wrought steel Fittings
IS1239 Part 2 Specification For Mild Steel Tubes, Tubulars and other Wrought steel
Fittings

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National Association of Corrosion Engineers (NACE)

MR0175/ Materials for use in H2S-containing environments in oil & gas production.
ISO 15156
MR0103 Materials resistant to Sulphide Stress Cracking in Corrosive Petroleum
Refining Environments
RP0175 Control of Internal Corrosion in Steel Pipelines and Piping Systems.
RP0472 Methods and controls to prevent in service environmental cracking of
carbon steel weldments in corrosive Petroleum Refining environment.
4. EXCEPTIONS TO SPECIFIED REQUIREMENTS

4.1. Exceptions to the specified requirements of the enquiry package will only be considered by the buyer
on a case by case basis for equipment or materials procured within the State of India, provided that the
equipment or the materials comply with applicable Indian codes and standards.
5. GENERAL REQUIREMENTS
5.1. All material shall be new and unused and shall be free of detrimental foreign matter.
5.2. Supplier shall fully describe all proposed deviations from this specification and referenced Codes,
standards and specifications for review and approval by EESL.
5.3. The carbon content of all carbon steel and impact tested carbon steel shall be limited to maximum of
0.25%, and a maximum carbon equivalent of 0.43 wt % where
CE = C + Mn + Cr + Mo+ V + Ni + Cu
6 5 15
5.4. Carbon content of type 304H, 321H and 347 stainless steels shall be minimum 0.04 weight percent.
5.5. Copper & copper alloy shall not be used.
5.6. Flanges face finish for raised-face & flat face flanges shall be as per MSS SP-6. Flanges with
SMOOTH finish shall have 125 to 250 RMS. Flanges with SERRATED finish shall have spiral or
concentric serrations, with 250 to 500 RMS finish. For ring type joint, the side wall surface of gasket
groove shall be as per ASME B16.5.
5.7. For flanges of ring type joint face the minimum hardness shall be as under.
Carbon Steel 120 Brinell
Low Alloy Steel 1% to 5% CR 160 Brinell

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The drawing, design and details given on this format are the property of ESSAR ENGINEERING CENTRE. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, Stainless Steel Type 304, 316, 321 & 347 160 Brinell
Stainless Steel Type 304L & 316L 140 Brinell
5.8. Lever operated valves (such as butterfly, ball, plug etc.) shall have a positive indicator for the
OPEN/CLOSE position. The operator shall be equipped with OPEN/CLOSE position locking device
suitable for locking with an ordinary lock and key.
5.9. Soft-seated valves to be used in inflammable services shall be fire safe designed conforming to API
607.
5.10. Soft-seated valves to be used in flammable services shall have plug/ball, stem and lever
electrostatically grounded to the valve body.
5.11. The bolting requirements for all valves shall be as mentioned below:
Valve Body Material Bolting Material
A 351 Gr. CF8M / A182 Gr. F304 Stud Bolt & Hex Nut ASME B18.2.1 A193 B8M
Cl.1/A1948MA
A351 Gr. CG3M / A182 Gr. F317L Stud Bolt & Hex Nut ASME B18.2.1 A193 B8M
Cl.2/A1948MA
A351 Gr. CF10M / A182 Gr. F316H Stud Bolt & Hex Nut ASME B18.2.1 B166 N06600
Annealed
A 351 Gr. CF8C / A182 Stud Bolt & Hex Nut ASME B18.2.1 A453 660A /
Gr.F321/F347 A1948TA
A 216 Gr. WCB Stud Bolt & Hex Nut ASME B18.2.1 A193 B7 & A194
Gr. 2H
A352 Gr.LCB / A350 Gr. LF2 Stud Bolt & Hex Nut, ASME B18.2.1, A320 L7 / A194 4
All Alloy steel Material Stud Bolt & Hex Nut ASME B18.2.1 A193 Gr. B16 &
A194 Gr. 4
For all other SS material Not Stud Bolt & Hex Nut ASME B18.2.1 A193 B8 Cl.2 &
mentioned above A194 Gr. 8
6. DESIGN
6.1. GENERAL
6.1.1.BASIC INFORMATION
Valve type, class, nominal size, bore, end connections, materials and other specific design
details are specified in the relevant Data Sheet / Requisition Description.
6.1.2.PRESSURE TEMPERATURE
The rating shall in general comply with ASME B16.5 or ASME B16.34.
6.1.3.GASKETS
6.1.3.1. Use of Gaskets containing asbestos is not allowed.

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The drawing, design and details given on this format are the property of ESSAR ENGINEERING CENTRE. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, 6.1.4.STUFFING BOXES.
6.1.4.1. The inside of the stuffing box shall have a maximum surface roughness (RA) of
0.8 micrometers preferably to ASME B46.1. and shall have burnish mirror finish
6.1.4.2. The bottom of the stuffing box shall be flat and square to the stem axis.
6.1.5.PRESSURE SEAL
6.1.5.1. The design of the pressure seal joint should be in accordance with ASME B
16.34.The pressure seal designs shall have a segmented thrust ring which locks into
the body. Contruction details are subject to approval by the EESL. However other
features shall be as per the design standard monitored in DS.
6.1.6.OPERATION
6.1.6.1. Manually operated valves shall not require a torque exceeding 350N-m on the hand
wheel or wrench to operate the valve.
6.1.6.2. Gear drives shall be enclosed in weatherproof gear operations with visible
OPEN/CLOSE indicator
6.1.6.3. Hand wheel orientation of gear operated valves will be specified on the outline
drawings for approval.
6.1.6.4. Valve sizes mentioned in the table below should have gear operation.
ASME BALL GATE GLOBE PLUG BUTTERFLY

CLASS VALVES VALVES VALVES VALVES VALVES
150 ≥8” ≥14” ≥14” ≥6” ≥8”
300 ≥6” ≥14” ≥14” ≥6” ≥6”
600 ≥4” ≥12” ≥12” ≥4” ≥4”
900 --- ≥10” ≥8” ≥3” ---
1500 --- ≥8” ≥6” ≥2” ---
2500 --- ≥6” ≥4” ≥2” ---
6.1.7.All valve castings shall be of radiographic quality as per applicable Inspection level table 1 for
General service & table 2 for Special Service
For Stainless steel valves casting shall be solution heat treated in pickled condition.
Casting shall be preheated to min 400˚ F prior to welding and Low Alloy Steel shall
be PWHT after welding. Stress relieving to be performed for all.

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The drawing, design and details given on this format are the property of ESSAR ENGINEERING CENTRE. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, Repair of defective casting shall be informed before repair and same shall
be repaired after getting approval.
6.2. VALVES IN HYDROGEN SERVICE

6.2.1.Hydrogen with a partial pressure of 7 kg/cm2 absolute and above or service containing 90
% hydrogen or higher at any pressure level.
6.2.2. The geometry of the valve internals shall be designed in order to avoid crevices and stagnant
zones.
6.2.3.Threaded body end connections are not acceptable.
6.2.4.Metal seats shall be welded-in for sizes 2” and larger
6.2.5.Threaded and/or seal welded bonnet/cover connections are not allowed.
6.2.6.A welded bonnet shall have a full penetration weld.
6.2.7.Back seats shall be integral or welded-in.
6.2.8.Valves with an integral or welded body-bonnet may be provided with a floating back seat.
6.2.9.Hard facing shall have a minimum finished thickness of 1.6 mm

6.2.10. Valves shall not be provided with sealant connections, unless specified otherwise.
6.2.11. Rating ≥900# shall be examined with 7.2 through 7.5 of sec VIII DIV-1 appendix VII
regardless of quality factor.
6.2.12. CS shall be normalized .Alloy steel shall be normalized plus tempered.
6.2.13. For CS & AS - Bend test & MP inspection of entire body and bonnet casting
shall be done as per ASTM 217.S3 & S4 evaluation of MP inspection shall be
as per MSS-SP-S3 except that no linear discontinuities are allowed.
6.2.14. Hardness requirement shall be as per MR0103
6.2.15. For valves above 220˚ C API 941 shall be followed.
6.2.16. All CS used should be Killed CS.
6.2.17. Deleted.
6.2.18. For hydrogen service or service having hydrogen, material should also comply the
requirement of API 941.
6.3. VALVES IN VACUUM SERVICE
6.3.1.Standard valves shall be used
6.3.2.Valves shall not be provided with sealant connections.
6.3.3.For vacuum design, the minimum differential external pressure shall be 15psi (1.05kg/cm2).
6.4. VALVES IN CRYOGENIC SERVICE

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The drawing, design and details given on this format are the property of ESSAR ENGINEERING CENTRE. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, 6.4.1.Valves in cryogenic services shall be provided with an extended bonnet with a vapor space
between valve body and stem packing. For valves in services between -50 deg C to -100 deg
C the vapor space length shall be at least:
VALVE SIZE ½-1 1 ½-2 3-4 6-8 10-12 14 AND

(INCH) UP
VAPOR SPACE 100 125 150 175 200 250
LENGTH (MM)
6.4.2. For valves in a service from – 100 deg C to -200 deg C the minimum vapor space length
shall be
VALVE SIZE ½-1 1 ½-2 3-4 6-8 10-12 14 AND
(INCH) UP
VAPOR SPACE 200 250 300 350 400 500
LENGTH (MM)
6.4.3. For cryogenic service long bonnet valves to be used.
6.4.4. Valves for cryogenic service having temperature range -50 ˚C to -196 ˚C shall follow
BS 6364.
6.5. JACKETED VALVES
6.5.1.Valves shall be fully steam jacketed. Each valve jacket shall have steam supply and condensate
return connection and a third connection for jump over. Size of the connections shall be
½”NB socket weld. Orientation shall be given at later stage.
6.5.2.Jacketed valves shall be provided with oversized flanges as indicated in table below.
VALVE SIZE FLANGE SIZE
(NB) (NB)
1” 2”
1 ½” 3”
2” 3”
3” 5”
4” 6”
6” 8”
8” 12”

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The drawing, design and details given on this format are the property of ESSAR ENGINEERING CENTRE. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, 10” 14”
6.6. VALVES FOR FLARE SERVICES:

Wherever ‘Flare piping’ is specified, the following conditions shall apply for body material.
a) C<0.23%, S<=0.025%, Mn<1.3%.
b) Base material hardness to be maintained up to 22HRC and hardness at weld metal as well as
HAZ to be up to 200BHN.
c) PWHT is required.
7. INSPECTION AND TESTING

GENERAL
a) QAP to be submitted by vendor.
b) All valves shall be inspected during manufacturing stage, start from identification of raw material
to completion. Proper documentation shall be maintained and shall be submitted.
c) Inspection of casting /forging/spindle and trim material received from sub supplier by co-relating
test certificate and check analysis where ever required.
d) Parts of valves e.g. bonnet, wedge etc, shall be inspected prior to assembly of valve for
workmanship.
e) Water with corrosion inhibitor or kerosene shall be used as test medium for hydro test.
f) Test performed in presence of purchaser’s representative shall not relieve
the supplier of their own responsibility and guarantee and any other contractual/ code obligation.
7.1. INSPECTION LEVELS
Valves and valve parts shall be inspected / tested according to the examination procedures and to the
extent as indicated in table 1, for valves in general service, or table 2, for valves in special service.
Ultrasonic examination instead of radiographic examination may be applied when the configuration
precludes radiography.
The following services are classified "special" and shall be indicated as such in the requisition:
a) Hydrogen Service: Hydrogen service is defined as a process stream with a hydrogen partial pressure of
100 psia [7.0 kg/ cm2 (a)] or greater or service containing 90% hydrogen or higher at any pressure
level and shall be indicated by ‘Hydrogen’ service in requisitions/datasheets.

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b) Hydrogen Sulfide (H2S) Service: H2S service is defined as a process stream containing either of the
following conditions and shall be indicated by ‘NACE’ service in requisitions/datasheets.
(1) H2S in a concentration greater than 0.3 mole percent with an aqueous phase
(2) Where liquid water is present containing greater than 10 ppm of H2S
c) Hydrofluoric Acid (HF) Service:

HF service is defined as a process stream containing any concentration of HF acid.
d) Amine Service
Amine service is defined as monoethanolamine (MEA), diethanolamine (DEA), and other
amines in solutions of greater than 2 weight percent.
e) Toxic Service
Toxic service is defined as in Category M Fluid Service per ASME B31.3, Paragraph 300.2 and shall
be indicated by ‘Bellow Sealed’ in the requisitions/datasheets.
f) Severe Cyclic Service
Severe cyclic service is defined as per the conditions of the piping system per ASME B31.3 Paragraph
300.2.
g) Critical services as defined by the EESL.
7.2. CATEGORY OF VALVES

Category A
Valves for:
Pressure class 150, 300 : Up to 24”.
Pressure class 600, 900 : Sizes up to and including 1 ½”
Category B
Valves for:
Pressure classes 150,300 : Sizes above 24”.
Pressure classes 600, 900 : Sizes 2" and up.
Pressure classes 1500, 2500: All sizes.
Table 1 - Inspection Levels for Valves in General Service

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The drawing, design and details given on this format are the property of ESSAR ENGINEERING CENTRE. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, CARBON FERRITIC AUSTENITIC NON
AND LOW- ALLOYS 1 ALLOYS FERROUS
MATERIAL OF COMPONENT
ALLOY ALLOYS
STEELS
Category of Valves A/B A/B A/B A/B
Visual inspection 3; 4 100 % 100 % 100 % 100 %

3
Castings: Radiography. 10 % 10 % 10 % 10 %
3
Forgings: Radiography. zero zero zero zero
2;3
Welds: Radiography 10 % 10 % 10 % 100 %
4
Weld Liq. penetrant 10 % 10 % 10 % 10 %
overlays:
Impact testing: when required by the applicable material standard
5
Hardness testing 10 % 10 % 10 % 10 %
Alloy verification as per the manufacturer’s practice
Notes:
1. Including:
• Duplex stainless steel.
• 13 Cr steel.
2. For fabricated (e.g. from plate) valves only.
3. Body, bonnet, cover.
4. Closure members such as gate/wedge, disc, ball, plug and seat rings.
5. When required by the applicable material standard (NACE).
Table 2 - Inspection Levels for Valves in Special Service
MATERIAL OF CARBON FERRITIC AUSTENITI NON

1
COMPONENT AND ALLOY ALLOYS C ALLOYS FERROU
STEELS S
ALLOYS
Category and percentage of samples A/B A/B A/B A/B

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The drawing, design and details given on this format are the property of ESSAR ENGINEERING CENTRE. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, Visual inspection 3; 4 100 100 100 100
Castings: Radiography 3; 6;7 100 100 100 100
Forgings: Radiography Zero Zero Zero Zero
Butt 2;3 Radiography 10/100 100 100 100
welds:
4
Weld Liq. penetrant 100 100 100 100
overlays:
Impact testing: When required by the applicable material standard
Hardness testing 5 10 10 10 10
Alloy verification as per the manufacturer's practice
Notes:
1. Including:
• Duplex stainless steel.
• 13 Cr steel.
2. For fabricated (e.g. from plate) valves only.
3. Body, bonnet, cover.
4. Closure members such as gate/wedge, disc, ball, plug and seat rings.
5. When required by the applicable material standard (NACE).
6. Critical areas only, as defined in ASME B16.34.
7. ASME Class 900 and greater cast valve assemblies and integral flanges in hydrogen service shall have
a casting quality factor of 100 percent. The examination shall be performed by radiography in
accordance with ASME Section VIII, Division 1, and Appendix 7. For 2 inch and smaller valves, if
radiography is not possible, a helium mass spectrometer test (probe technique) in accordance with
ASME Section V, Subsection A, Article 10, Appendix V is acceptable. Casting repairs and
identification shall meet the requirements of 7-4 and 7-5 of Appendix 7 of ASME Section VIII,
Division 1.
7.3. ACCEPTANCE CRITERIA
7.3.1.GENERAL
Examinations shall be in accordance with the procedures as indicated in this specification
and shall be carried out after any required heat treatment but prior to or in the final
(machined) condition, unless specified otherwise.

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The drawing, design and details given on this format are the property of ESSAR ENGINEERING CENTRE. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, 7.3.2.VISUAL EXAMINATION
Body, bonnet or cover and closure members shall be visually examined as per MSS SP-55.
7.3.3.LIQUID PENETRANT AND MAGNETIC PARTICLE EXAMINATION
Liquid penetrant and magnetic particle examination procedures shall conform to the ASME
section V, articles 6, 7, 24 and 25 as applicable. Acceptance criteria for body, bonnet or
cover and closure members shall be as per ASME B16.34, annexes C and D as applicable.
Exterior and accessible interior surfaces shall be examined in the final (machined) condition.
Prods for magnetic particle examination shall not be used on any sealing or sliding surfaces.
For Dye Penetration test ASTM E 165 procedure B2 interpretations as per appendix 8 of
VIII Div 1.to be used.
Stellited trim valves shall have 100% Dye Penetration test.
7.3.4.RADIOGRAPHIC EXAMINATION
Radiographic examination procedures shall conform to ASME; section V, articles 2 and 22.
Acceptance standards concerning discontinuities and severity levels for body, bonnet or
cover shall be as shown in table 3 for valves in special service. For a definition of special
service see subsection 7.1. Acceptance standard for butt welds shall be in accordance with
ASME B31.3. Table 341.3.2A, for fluid services other than special services mentioned in
Section 7.1.
Table 3 - Valves in Special Service
REFERENCE PLATES
FLAW CATEGORY ASTM E-446/186/280
BUTT WELD ENDS OTHER CRITICAL AREAS
AND BUTT WELDS VALVES UP VALVES
TO NB 250 NB 300 AND UP
Gas, blow holes, porosity A 2 2 3
Sand spots, inclusions B 2 2 3
Internal shrinkage C

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The drawing, design and details given on this format are the property of ESSAR ENGINEERING CENTRE. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, CA type 1 linear 2 2 3
CA type 2 dendritic 2 2 3
CA type 3 spongy 2 2 3
CA type 4 2 2 3
Hot tears/linear discontinuities D 0 0 0
Crack/linear discontinuities E 0 0 0
Infused chap-lets/inserts F 0 0 0
Internal chills/inserts G 0 0 0
7.3.5. ULTRASONIC EXAMINATION

Ultrasonic examination procedures shall conform to ASME section V, articles 5 and 23.
Acceptance criteria for body, bonnet or cover shall as per ASME B16.34, annex E.
7.3.6. HARDNESS
When sour service (NACE) conditions are specified, hardness requirements as described in
NACE standard MR 0103 shall be met for any process-wetted part of the valve and pressure-
retaining bolting.
For all other services the maximum allowable hardness shall be:
• Base metal, welds and HAZ (Heat Affected Zone) of pressure-containing parts: 248 HV.
• Base metal of internals with "hard facing" weld deposits: 350 HV.
• 13 Cr steel internals: 350 HV.
• Austenitic Stainless Steel: 248HV.
Approved methods for hardness measurements are the standard hardness tests or the
following portable methods: Equo-tip, Diamond-tip and Tele-Brinell (use of these methods
shall be within the limits of their application). Other methods shall be approved by the
EESL. Hardness indentations shall be avoided on any sealing or sliding surfaces.
7.3.7.IMPACT TESTING
Tests shall be according to the specification for the material concerned. Impact tests may be
executed on specially made test pieces from the same heat/batch which are simultaneously
subjected to the same heat treatment as the base material.

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The drawing, design and details given on this format are the property of ESSAR ENGINEERING CENTRE. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, • CHARPY-V REQUIREMENTS:
Charpy V notch testing is to be done for valves average (20 ff-lb for set of 3)
(min value 15ft-lb at 30 deg F).
As per applicable standards:
Additionally for ASTM A182M-GR.F11-Class 2, F22-Class 3 and ASTM A217-WC6,
WC9 (Only applicable for thicknesses over 50 mm and in the final condition). For all
materials, including the weld metals, a Charpy-V notch energy absorption value of 55 joule
average and 48 joule minimum at minus 40°C are to be specified. The test specimens are to
be taken from the transverse direction at 1/4 and 1/2 of the thickness.
7.3.8.ALLOY VERIFICATION
Verification may be carried out by chemical, spectroscopic or X-ray fluorescence methods.
The alloy verification procedure shall be approved.
7.3.9.CORROSION TESTING
• Austenitic and austenitic/ferritic stainless steels and nickel alloys shall be capable of
passing an intergranular corrosion test in accordance with ASTM A262 as follows:

• Austenitic and austenitic / ferritic stainless steels as per practice E.
• Nickel alloys (UNS N08028, N06625 and N08825) as per practice C.
• The average corrosion rate shall not exceed 0.3 mm/y.
7.4. HYDROGEN INDUCED CRACKING (HIC) REQUIREMENTS:

Wherever Hydrogen Induced Cracking (HIC) is indicated, following requirement shall be
complied with:
• Material shall be as per NACE MR0175/ISO 15156
• All forged & cast material shall have sulphur level less than 0.025%.
7.5. ADDITIONAL TESTS FOR VALVES IN HYDROGEN SERVICE AND FOR VALVES WITH
LIVE LOADED STUFFING BOXES.
7.5.1.GENERAL INFORMATION
• Test valves shall be selected at random from the total lot of valves, taking into account
type, size and pressure class as much as possible. The total number of samples from the lot
shall be 10%, but with a minimum of one per type or as specified otherwise by the EESL.
• Valves shall be tested at:
• The manufacturer's works, or

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The drawing, design and details given on this format are the property of ESSAR ENGINEERING CENTRE. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, • An independent testing facility.
• All valves to be tested and 10% observed.
• Valves shall be degreased before Helium testing.
• Valves shall have already successfully passed the normal production tests as per the
applicable design standard and specification in ASME SEC V article 10 appendix IV
• If a valve fails to meet any of the test requirements, the valve shall be rejected, all obtained
data and findings shall be recorded and submitted to the EESL.
• If the test equipment fails or a shortage of gas (bottle/supply) occurs, the test shall be
aborted and the valve shall be submitted to a retest.
7.5.2.TEST RIG AND INSTRUMENTS
• Valve manufacturer shall propose diagrammatically a suitable test rig for approval by the
EESL. The test medium shall be helium gas. Generally, min 10% helium by volume and
dry air 90% max {used as a trace for leak detection) is applicable. The mix of gas shall be
stated in the test record.
• Note: Attention is drawn to the hazardous nature of pneumatic testing.

• The range of the test pressure gauges shall not be more than twice the test pressure.
• Leakage through the valve shall be measured by means of:
• A measuring cylinder.
• A glass flow meter soap film type.
• A flow Rotameter.
• The valve should be tested by Detector probe technique as per ASME Sec-V, article-10
• The probe shall be held very close to the examination surface and distance of probe shall
not exceed 3mm.
7.5.3.PREPARATION PRIOR TO TESTING
• The test equipment and valve shall be dry and free of oil and dust.
• The valve shall be visually inspected for any damage, defects, etc.
• The valve shall not have any protective coating on the valve body and internals. If a
protective coating has to be removed, the valve shall be disassembled and the valve body
and internals shall be thoroughly cleaned and degreased with inhibited methylene chloride
or trichloroethylene.
• After reassembly, the valve shall be re-qualified to the requirements of the applicable
design standard and specification.

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The drawing, design and details given on this format are the property of ESSAR ENGINEERING CENTRE. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, • The valve ends shall be equipped with suitable end covers, capable for testing in both
directions. Both covers shall be provided with a pressure/vent connection.
• Brackets to support the valve in the test rig shall be fixed to the end covers or alternatively
clamped to the body. There shall be no support mounted to the bonnet of the valve.
• Leakage of the valve and test equipment to the outside shall be detected by means of a
mass spectrometer provided with a sniffer probe, or other method suitable for helium leak
detection. Other detection methods are subject to approval by the EESL. All measuring
equipment and instruments shall have a valid calibration certificate from accredited
agencies.
• Leakage rate of 1x10 -4 std cc/sec is acceptable.
7.5.4.TEST PROCEDURES AND REQUIREMENTS

GENERAL
• The tests shall be carried out in the sequence as stated in para 7.5.5.
• All test data shall be recorded.

• Valves, except check valves, shall be seat tested in both directions. Check valves are uni-
directional and shall be tested as such.
• Operation of the valve (open-close)
• Full operation of the valve shall not take more than the maximum time specified by the
manufacturer.
• Manually operated valves shall be operated without the use of spanners.
• Check valves need not to be opened and closed.
• The maximum torque applied at the wrench or hand wheel, for operation of the valve
during the maximum differential test pressure, shall not exceed 35 kgf-m.
7.5.5.TIGHTNESS TEST AT AMBIENT TEMPERATURE

Low Pressure seat test: Internal Leakage Test.
• This test is not required for control valves.
• The valve shall be in the closed position. Subject the valve to a test pressure of 0.5 kg min
should be helium...
• Valves with a cavity shall be opened and closed in order to equalize the cavity pressure.
The downstream system of the valve shall be depressurized at the beginning of each test.

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The drawing, design and details given on this format are the property of ESSAR ENGINEERING CENTRE. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, • The leakage through the valve shall be measured at 2 kg/cm2 and 7 kg/cm2 during a
period of at least 5 minutes after the pressure has stabilized. The allowable leakage rates
shall be in accordance with BS 6755, Part 1, Rate B (for metal seated valves) or API 598
• Shell test-external leakage test.
• The valve shall be in the half open position. Subject the valve to a pressure equal to 25%
of the allowable (rated) cold working seat pressure. The pressure shall remain stable
throughout the test duration.
• The entire valve shall be checked for leakage to the outside, especially at
body/bonnet/cover joints and the stuffing box.
• The test duration shall be as follow
TEST DURATION IN MINUTES
Nominal Size Pressure Class

150/300 600/800 900 1500 2500
Up to and including 2" 3 6 9 12 12
3" up to and including 6" 6 9 12 15 18
• The valve shall show no leakage. No leakage is defined as a total leakage rate of less than
0.0001 ml/s of helium.
7.5.6.POST-TEST EXAMINATION
• The valve shall be visually inspected for any damage, etc.
• Any specific observations shall be recorded in the test record as shown hereafter.
7.5.7.SAMPLE TEST REPORT

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The drawing, design and details given on this format are the property of ESSAR ENGINEERING CENTRE. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, Leakage Acceptance Test
Valve Test Record/Certificate
Inspection authority :
Report reference no. : Date of test :
Valve manufacturer : Type of valve :
Contractor : Size :
Contractor's order no. : Class rating :
Valve identification : Seat material :
Design standard : Body material :
Test Requirements and limits Results
(Specified Limits) (Actual)
Low pressure seat test at Leakage : ml/s

ambient temperature test internal through less than
medium : the valve ml/s
Pressure 7 kg/cm2
Shell test at ambient Leakage : Test duration: Min.
temperature test medium :
external to the outside zero or less ml/s
2
Pressure kg/cm - stem seal than ml/s
- bonnet joint 0.0001 ml/s ml/s
- valve body
Valve examination Observations and Findings.
Inspection Authority signature: Date:
7.6. ADDITIONAL TESTS FOR VALVES IN VACUUM SERVICE

All the requirements of section 7.4 are to be followed. In addition to that following requirements are
also to be fulfilled.
7.6.1.GENERAL INFORMATION

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The drawing, design and details given on this format are the property of ESSAR ENGINEERING CENTRE. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, • Test valves shall be selected at random from the total lot of valves, taking into account
type, size and pressure class as much as possible. The total number of samples from the lot
shall be 10%, but with a minimum of one per type or as specified otherwise by the
contractor.
• The valves shall be tested at:
• The manufacturer's works, or
• An independent testing facility.
• All valves to be tested and 10% observed.
• Valves shall be degreased before Helium testing.
• Valves shall have already successfully passed the normal production tests as per the
applicable design standard and specification in ASME secV article 10.
• If a valve fails to meet any of the test requirements, the valve shall be rejected, all obtained
data and findings shall be recorded and submitted to the EESL.
• If the test equipment fails or a shortage of gas (bottle/supply) occurs, the test shall be
aborted and the valve shall be submitted to a retest.
7.6.2.TEST RIG AND INSTRUMENTS

• Valve manufacturer shall propose diagrammatically a suitable test rig for approval by the
EESL. The test medium shall be helium gas. Generally, min 10% helium by volume and
dry air 90% max (used as a trace for leak detection) is applicable. The mix of gas shall be
stated in the test record.
• Note: Attention is drawn to the hazardous nature of pneumatic testing.
• The range of the test pressure gauges shall not be more than twice the test pressure.
• Leakage through the valve shall be measured by means of:
• A measuring cylinder.
• A glass flow meter soap film type.
• A flow Rotameter.
• The valve should be tested by tracer probe technique as per ASME Sec-V, article-10.
• The probe shall be held very close to the examination surface and distance of probe shall
not exceed 3mm.

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The drawing, design and details given on this format are the property of ESSAR ENGINEERING CENTRE. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, 7.6.3.PREPARATION PRIOR TO TESTING
• The test equipment and valve shall be dry and free of oil and dust.
• The valve shall be visually inspected for any damage, defects, etc.
• The valve shall not have any protective coating on the valve body and internals. If a
protective coating has to be removed, the valve shall be disassembled and the valve body
and internals shall be thoroughly cleaned and degreased with inhibited methylene chloride
or trichloroethylene.
• After reassembly, the valve shall be requalified to the requirements of the applicable
design standard and specification.
• The valve ends shall be equipped with suitable end covers, capable for testing in both
directions. Both covers shall be provided with a pressure/vent connection.
• Brackets to support the valve in the test rig shall be fixed to the end covers or alternatively
clamped to the body. There shall be no support mounted to the bonnet of the valve.
• Leakage of the valve and test equipment to the outside shall be detected by means of a
mass spectrometer provided with a sniffer probe, or other method suitable for helium leak
detection. Other detection methods are subject to approval by the EESL. All measuring
equipment and instruments shall have a valid calibration certificate
• Leakage rate of 1x10 -4 std cc/sec is acceptable.
7.6.4.TEST PROCEDURES AND REQUIREMENTS

GENERAL
• The tests shall be carried out in the sequence as stated in para 7.6.5.
• All test data shall be recorded.
• Valves, except check valves, shall be seat tested in both directions. Check valves are uni-
directional and shall be tested as such.
• Operation of the valve (open-close)
• Full operation of the valve shall not take more than the maximum time specified by the
manufacturer.
• Manually operated valves shall be operated without the use of spanners.
• The maximum torque applied at the wrench or hand wheel, for operation of the valve
during the maximum differential test pressure, shall not exceed 35 kgf.m
• Check valves need not to be opened and closed.

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7.6.5.VACUUM TEST AT AMBIENT TEMPERATURE

• The valve shall be in the half open position. Subject the valve to a vacuum of 0.0001
kg/cm2. The vacuum shall remain stable throughout the test duration.
• Test duration shall be as follows:
TEST DURATION IN MINUTES
Nominal Size Pressure Class
150/300 600/800 900 1500 2500
Up to and including 2" 3 6 9 12 12

• The valve shall show no leakage. No leakage is defined as a total leakage rate of less than
0.0001 ml/s of helium.
7.6.6.POST-TEST EXAMINATION
• The valve shall be visually inspected for any damage, etc.
• Any specific observations shall be recorded in the test record as shown hereafter.
7.6.7.SAMPLE TEST REPORT

Vacuum Acceptance Test
Valve Test Record/Certificate
Inspection authority :
Report reference no. : Date of test :
Valve manufacturer : Type of valve :
Contractor : Size :
Contractor's order no. : Class rating :

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The drawing, design and details given on this format are the property of ESSAR ENGINEERING CENTRE. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, Valve identification : Seat material :
Design standard : Body material :
Test Requirements and limits Results
(Specified Limits) (Actual)
Vacuum test Leakage : less than ml/s
at ambient temperature ml/s
test medium :
Pressure 0.0001 kg/cm2 abs

Valve examination Observations and findings.
Inspection Authority signature: Date:
8. CLEANING
Valves for hydrogen service and/or vacuum service shall be internally clean and free from moisture
and grease.
9. PAINTING
9.1. Carbon and low alloy steel valves shall be painted or coated in accordance with the manufacturer's
standard.
9.2. Stainless steel and nonferrous valves shall not be painted or coated.
10. DOCUMENTATION
10.1.Documentation shall be provided as specified in the requisition.

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The drawing, design and details given on this format are the property of ESSAR ENGINEERING CENTRE. They are merely loaned on the borrower's express agreement that they will not be reproduced, copied, 11. PREPARATION FOR SHIPMENT
11.1. Machined or threaded surfaces shall be coated with an easily removable rust protective fluid e.g.
Shell ensis MD or equivalent.
11.2. Valve ends shall be covered with suitable close fitting protectors {e.g. plastic caps) to protect the
machined parts and prevent ingress of dirt and moisture.
11.3. For gate valves, the wedge shall be fully closed before shipping.
11.4. For globe valves, the disk shall be fully closed before shipping.
11.5. For check valves 2" and larger, the disk shall be secured in the closed or open position to prevent
damage.
11.6. The stuffing box shall be protected against the ingress of water (e.g. with plastic caps, bags or tapes)
11.7. . MARKING
11.7.1. Valves in hydrogen service shall be provided with a label, stating the hydrogen service
application of the valve.
11.7.2. Valves in vacuum service shall be provided with a label stating the vacuum service
application of the valve.
11.8. Flanged and Butt welded ends shall be protected by means of metal /wooden plates or caps securely
fastened to valves.
11.9. Plastic caps are acceptable for small bore only.
11.10. Painting shall be done only after inspection.
11.11. Hand wheel, 6" and larger shall be removed and wired to the walls.
11.12. The packing case shall be marked with purchase order No. and shall include complete packing
list of all items contained in the list.
11.13. Sample Drawing shall be submitted with offers.

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Technical Supply Conditions For Valves

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Technical Supply Conditions For Valves

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-

E2 VADINAR REFINERY EXPANSION

PROJECT DOCUMENT NO.

25/04/07 ISSUED FOR REVIEW 00

TECHNICAL SUPPLY CONDITIONS FOR EESL DOCUMENT NO

TECHNICAL SUPPLY CONDITIONS FOR EESL DOCUMENT NO

2. CONFLICTS AND DEVIATIONS

• Referenced Codes and Standards.

TECHNICAL SUPPLY CONDITIONS FOR EESL DOCUMENT NO

American Petroleum Institute (API)

Manufacturers Standardisation Society (MSS)

TECHNICAL SUPPLY CONDITIONS FOR EESL DOCUMENT NO

American Society for Testing Materials (ASTM)

International Organisation for Standardisation (ISO)

Indian Standards and Regulations (IS)

TECHNICAL SUPPLY CONDITIONS FOR EESL DOCUMENT NO

National Association of Corrosion Engineers (NACE)

4. EXCEPTIONS TO SPECIFIED REQUIREMENTS

TECHNICAL SUPPLY CONDITIONS FOR EESL DOCUMENT NO

TECHNICAL SUPPLY CONDITIONS FOR EESL DOCUMENT NO

ASME BALL GATE GLOBE PLUG BUTTERFLY

TECHNICAL SUPPLY CONDITIONS FOR EESL DOCUMENT NO

6.2. VALVES IN HYDROGEN SERVICE

6.2.9.Hard facing shall have a minimum finished thickness of 1.6 mm

TECHNICAL SUPPLY CONDITIONS FOR EESL DOCUMENT NO

VALVE SIZE ½-1 1 ½-2 3-4 6-8 10-12 14 AND

TECHNICAL SUPPLY CONDITIONS FOR EESL DOCUMENT NO

6.6. VALVES FOR FLARE SERVICES:

7. INSPECTION AND TESTING

7.1. INSPECTION LEVELS

TECHNICAL SUPPLY CONDITIONS FOR EESL DOCUMENT NO

c) Hydrofluoric Acid (HF) Service:

Amine service is defined as monoethanolamine (MEA), diethanolamine (DEA), and other

amines in solutions of greater than 2 weight percent.

be indicated by ‘Bellow Sealed’ in the requisitions/datasheets.

f) Severe Cyclic Service

g) Critical services as defined by the EESL.

7.2. CATEGORY OF VALVES

TECHNICAL SUPPLY CONDITIONS FOR EESL DOCUMENT NO

Category of Valves A/B A/B A/B A/B

Visual inspection 3; 4 100 % 100 % 100 % 100 %

Alloy verification as per the manufacturer’s practice

Table 2 - Inspection Levels for Valves in Special Service

MATERIAL OF CARBON FERRITIC AUSTENITI NON

TECHNICAL SUPPLY CONDITIONS FOR EESL DOCUMENT NO

TECHNICAL SUPPLY CONDITIONS FOR EESL DOCUMENT NO

Table 3 - Valves in Special Service

Gas, blow holes, porosity A 2 2 3

Sand spots, inclusions B 2 2 3

TECHNICAL SUPPLY CONDITIONS FOR EESL DOCUMENT NO

7.3.5. ULTRASONIC EXAMINATION

TECHNICAL SUPPLY CONDITIONS FOR EESL DOCUMENT NO

passing an intergranular corrosion test in accordance with ASTM A262 as follows:

7.4. HYDROGEN INDUCED CRACKING (HIC) REQUIREMENTS:

TECHNICAL SUPPLY CONDITIONS FOR EESL DOCUMENT NO

• Note: Attention is drawn to the hazardous nature of pneumatic testing.

TECHNICAL SUPPLY CONDITIONS FOR EESL DOCUMENT NO

7.5.4.TEST PROCEDURES AND REQUIREMENTS

• All test data shall be recorded.

7.5.5.TIGHTNESS TEST AT AMBIENT TEMPERATURE

TECHNICAL SUPPLY CONDITIONS FOR EESL DOCUMENT NO

TEST DURATION IN MINUTES

Nominal Size Pressure Class