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NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES J.06

CONTROL VALVES

Rev

Date

Description

Checked

Approved

0

1999

Issued for Implementation

PP

DL

Compiled by Teknica (UK) Ltd

GENERAL ENGINEERING SPECIFICATION CONTROL VALVES

INDEX

GES J.06 Page 2 of 20 Rev 0 1999

SEC

TITLE

PAGE

1.0

SCOPE OF SPECIFICATION

4

1.1

Introduction

4

1.2

Other NOC Specifications

4

1.3

Data Sheets

4

2.0

DEFINITIONS

5

2.1

Technical

5

2.2

Contractual

6

3.0

DESIGN

6

3.1

Codes and Standards

6

3.2

Valve Sizing

7

3.3

Valve Selection and Design

8

3.4

Globe & Angle Valves

9

3.5

Ball Valves

10

3.6

Butterfly Valves

10

3.7

Diaphragm Valves

11

3.8

Cam type Valves

11

3.9

Valves in Oxygen Service

11

3.10

Spring Diaphragm Actuators

11

3.11

Piston Actuators

12

3.12

Valve Positioners

12

3.13

Limit Switches

12

3.14

Limit Stops

12

3.15

Volume Boosters

13

3.16

Handwheels

13

4.0

MATERIALS

13

4.1

Valve Body

13

4.2

Valve Trim

13

4.3

Gaskets & Packing

14

4.4

Actuator

14

4.5

Sour Environments (NACE)

14

4.6

Material Certification

15

5.0

MANUFACTURER

15

5.1

QA/QC

15

5.2

Valve Body

15

6.0

INSTALLATION

15

6.1

Block & Bypass Valves and Manifolds

15

6.2

Valve Location

15

6.3

Pre-commissioning

16

SEC

TITLE

PAGE

GENERAL ENGINEERING SPECIFICATION CONTROL VALVES

GES J.06 Page 3 of 20 Rev 0 1999

7.0

INSPECTION

16

7.1

Procedures

16

7.2

Scope

16

7.3

Nameplates

16

7.4

Marking

17

8.0

TESTING

17

8.1

Statutory Tests

17

8.2

Test Procedures

17

8.3

Test Certificates

17

8.4

Hydrostatic Tests

18

8.5

Seat Leakage Tests

18

8.6

Hysteresis Tests

18

8.7

Deadband Tests

18

8.8

Stroking Time

18

8.9

Capacity Test

19

9.0

DOCUMENTATION

19

9.1

Introduction

19

9.2

Schedules and Reports

19

9.3

Data and Calculations

19

9.4

Drawings

19

9.5

Final Records, Documents and Manuals

19

10.0

PRIOR TO SHIPMENT

19

10.1

Painting and Coatings

19

10.2

Spares

20

10.3

Packing and Storage

20

10.4

Shipping

20

10.5

Warranty

20

ISA Forms

S20.50

 

S20.51

GENERAL ENGINEERING SPECIFICATION CONTROL VALVES

GES J.06 Page 4 of 20 Rev 0 1999

1.0

SCOPE OF SPECIFICATION

1.1

Introduction

1.1.1

This specification covers the minimum requirements for the design, specification, material selection, installation, inspection, testing, documentation and preparation for shipment of control valves.

1.1.2

This specification applies to equipment for refineries, onshore oil & gas installations and processing facilities including items purchased either directly or as part of a package.

1.1.3

The Vendor/Contractor shall comply fully with the provisions laid down in this specification. Any exception must be authorised in writing by the Owner.

1.1.4

In the event of any conflict between this specification and the data sheets, or with any applicable codes and standards, the Vendor/Contractor shall inform the Owner and obtain written clarification or authorization from the Owner before proceeding with the work.

1.1.5

This General Specification will form part of the Purchase Order/Contract.

1.2

Other NOC Specifications

The following NOC Specifications are an integral part of this specification and any exceptions shall be approved in advance by the Owner.

GES C.55

Field Installation, Calibration and Testing of Instruments

GES J.15

Instrument Air Supplies

GES L.31

Area Classification

GES L.35

Electrical Equipment in Hazardous Areas

GES P.02

Plant Piping Systems.

GES P.10

Erection and Testing of Steel Piping

GES X.06

Factory Coatings for Electrical Equipment and Instruments

1.3

Data Sheets

The technical data supplied by the Owner for the equipment is given on the Data Sheet which is included at the end of this specification. The Vendor/Contractor shall complete the Data Sheet with the remaining information.

2.0

DEFINITIONS

2.1

Technical

The technical terms used in this specification are defined as follows.

GENERAL ENGINEERING SPECIFICATION CONTROL VALVES

Cavitation

GES J.06 Page 5 of 20 Rev 0 1999

The collapse of vapour bubbles in the fluid after pressure recovery. Generates noise and can do physical damage to the valve.

Choked Flow

The condition at constant inlet pressure at which no increase in flow is achieved on reduction of the outlet pressure.

Critical Pressure Ratio

The critical pressure ratio is the pressure at the Vena Contracta divided by the inlet pressure.

C V

The valve flow coefficient. The number of U.S. gallons of water per minute, at 60°F (15.6°C) that a valve will pass at a pressure differential of 1 psi.

Flashing

The production of vapour bubbles in the fluid due to the pressure reduction in the control valve below the vapour pressure of the liquid can reduce valve capacity and cause physical damage to the control valve.

Mach

Ratio of velocity of fluid to the velocity of sound in the fluid.

Maximum Flow Rate

The extreme flow rate that may be experienced by the process.

Minimum Flow Rate

The minimum flow rate that may be experienced by the process.

Normal Flow Rate

The normal operating flow rate at material balance conditions as shown on the process flow sheet.

Pressure Recovery

The portion of velocity head that is recovered as pressure head after the Vena Contracta. The pressure recovery co-efficient is included in the valve sizing formula.

Vena Contracta

The point downstream of a flow restriction at which the flow stream is at its minimum cross-section and lowest pressure.

GENERAL ENGINEERING SPECIFICATION CONTROL VALVES

GES J.06 Page 6 of 20 Rev 0 1999

2.2

Contractual

 

The commercial terms used in this specification are defined as follows:

Owner

 

The oil or gas company, an associate or subsidiary, who is the end user of the equipment and facilities.

Vendor

 

The company supplying the equipment and material.

Contractor

 

The main contractor for a defined piece of work.

Sub-Contractor

 

A

company awarded a contract by a contractor to do part of the work awarded to the contractor.

Inspection Authority

 
 
 

The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and facilities have been designed, constructed, inspected and tested in accordance with the requirements of this specification and the Purchase Order/Contract.

Inspector

 

A

qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection Authority, who

verifies that the equipment and facilities have been designed, constructed, inspected and tested in accordance

with the requirements of this specification and the Purchase Order/Contract.

3.0

DESIGN

 

3.1

Codes and Standards

3.1.1

The design shall comply with this specification and the following codes and standards.

3.1.2

Unless otherwise specified in the Purchase Order/Contract, the current editions of the codes and standards at the time of the Purchase Order/Contract should be used.

American National Standards Institute

ANSI/FCI 70.2

Standard for Control Valve Leakage

ANSI/ISA 75.01

Flow Equations for Sizing Control Valves

ANSI/ISA 75.02

Valve Capacity Test Procedure

ANSI/ISA 75.03

Face to Face Dimensions for Flanged Globe Valves

ANSI/ISA RP 12.6:1987

ANSI/UL 1203:1988

Installation of Intrinsically Safe Instrument Systems Class I Hazardous Locations

Explosion-proof and Dust Ignition-proof Electrical Equipment for Use in Hazardous (Classified) Locations

GENERAL ENGINEERING SPECIFICATION CONTROL VALVES

American Petroleum Institute

GES J.06 Page 7 of 20 Rev 0 1999

API 6D

Specification for Pipeline Valves

API 6FA

Specification for the Fire Testing of Valves

American Society for Testing Materials

ASTM A 216

Carbon Steel Castings suitable for Fusion Welding for High Temperature Services.

British Standards

BS 5345 Parts 1-7

Selection, Installation and Maintenance of Electrical Apparatus in Explosive Atmospheres

BS 6755 Part 2

Specification for Fire - Type Testing

International Electrotechnical Commission

IEC 79 Parts 1-15

Electrical Apparatus for Explosive Atmospheres

IEC 534 Part 2

Flow Capacity. Sizing Equations for Incompressible Fluids

IEC 534 Part 3

Face to Face Dimensions for Flanged Globe Valves

IEC 534 Part 5

Industrial Process Control Valves Marking

IEC 534 Part 6

Mounting Details for Attachments of Positioners to Control Valves

IEC 534 Part 8

Industrial Process Control Valves Noise Considerations

IEC 60529

Degrees of Protection Provided by Enclosures (IP Code)

National Association of Corrosion Engineers

NACE MR-01-75

Material Requirement-Sulphide Stress Cracking Resistant Material for Oil field equipment

National Electrical Code

NEC, NFPA-70 Article 500

Hazardous (Classified) Locations)

3.2

Valve Sizing

3.2.1

Valves shall be sized by the Vendor/Contractor based on the data given in the data sheets, using the Vendor/Contractor's standard methods. The sizing calculations shall be in accordance with ISA S75.01:1977 or IEC 534 Part 2 and Part 2/2.

3.2.2

Intermediate capacity indexes or stem position shall be derived from the Vendor/Contractor's tables or test curves.

3.2.3

The results of the calculations, together with the selected valve type and discharge co-efficient, shall be submitted to the Owner for approval.

GENERAL ENGINEERING SPECIFICATION CONTROL VALVES

GES J.06 Page 8 of 20 Rev 0 1999

3.2.5

Linear valves shall be sized to pass normal flow at a valve travel of approximately 70%. Maximum flow shall occur at not greater than 90% of valve travel.

3.2.6

Where the pressure drop across a control valve is less than 30% of the total dynamic pressure drop, consideration should be given to other forms of flow control.

3.2.7

Where valves are mounted between pipe reducers, the calculated C V shall be reduced by a correction factor. The correction factor shall be obtained from the Vendor/Contractor.

3.2.8

Where the Reynolds number is below 12,000, the Vendor/Contractor shall, if necessary, correct the valve capacity for the effects of viscosity.

3.2.9

The cavitation or flashing condition in the control valve shall be determined in accordance with ANSI/ISA S75.01, Section 8.0. If cavitation cannot be eliminated, then a special valve with anti-cavitation trim shall be selected.

3.2.10

The minimum body size shall be 1 inch, except where the line size is less than 1 inch, in which case a line sized body may be used. The valve body may have the same size as the calculated trim, but shall not be smaller than one half of the line size. Where oversized bodies are used, for example, to reduce the outlet velocity, a reduced trim to the Vendor's/Contractor's standard may be used.

3.3

Valve Selection and Design

3.3.1

Globe valves shall be selected as standard except for applications with adverse operating conditions, e.g. very low or high pressure drops, high flow rates, fluids containing suspended solids, or corrosive fluids where body lining may be required.

3.3.2

Most control valves shall normally have equal percentage characteristics. In the following cases, however, the valves shall have linear characteristics:

- where the pressure drop across the control valve under all operating conditions is more than 2 / 3 of the pressure drop when the valve is closed, i.e. level control or linear flow control;

- surge control of compressors;

- split range control;

- parallel operation of valves;

- control valves operated from a manual control station;

- valves below 1 inch.

- as required by process considerations.

3.3.3

Valves used for on/off control shall have "quick opening" characteristics, unless otherwise specified. Other characteristics such as equal percentage or modified equal percentage may be used to avoid or reduce the effects of hydraulic shock.

3.3.4

Seat leakage classification shall be in accordance with ANSI/FCI 70.2. The leakage class shall be determined by the service and valve type. Soft seat valves may be considered for Class VI shut-off, where the temperature does not exceed 450°F (230°C), and where flashing does not occur.

3.3.5

Control valves above 2 inch, with the exception of wafer type butterfly valves, shall normally have flanged connections.

3.3.6

Flangeless bodies may be considered for applications requiring expensive or exotic materials.

3.3.7

The flange rating shall be in accordance with the piping class with a minimum rating of Class 300. This can be relaxed in the case of diaphragm valves, which because of their design, can only be used on low pressure services.

17°C).

GENERAL ENGINEERING SPECIFICATION CONTROL VALVES

GES J.06 Page 9 of 20 Rev 0 1999

3.3.9

Valve stem position or angle indicators shall be indicated on a graduated scale with the words "Open" and "Shut" at the valve travel limits.

3.3.10

The noise level should not exceed 85 dBA, measured at 3.3 ft (1 m) from the control valve body.

3.3.11

The gas flow velocity at the discharge flange shall not exceed 0.3 Mach. Where necessary, oversized valve bodies with reduced trim may be used to maintain this limit.

3.3.12

Valve stem dust protection bellows or gaiters may be specified in marine or dusty environments. The protection bellows or gaiters shall be of a hydrocarbon and salt-resistant material.

3.3.13

Where a fire-safe design is required, the valve shall meet the requirements of API 6FA or BS 6755: Part 2, and be fully witness tested and certified.

3.3.14

A valve in cavitation service shall not exhibit choked flow at any specified design condition. The valve shall be designed so that cavitation is minimised and confined to an area where it will not damage the valve or body, or trim or downstream piping.

3.4

Globe and Angle-body Valves

3.4.1

The trim construction for globe valves shall be either single seated with heavy duty top guiding, double seated with top and bottom guiding, or cage.

3.4.2

Globe valves used in throttling services where tight shut-off is required shall be single seat.

3.4.3

Soft or resilient seat shut-off control valves may be used on clean services when they conform to the pressure, temperature and chemical limitations of the process. The seat ring shall be properly clamped between metal parts and/or locked in position to prevent blow out in the closed position.

3.4.4

Double seat, balanced control valves may be used where it is necessary to limit the actuator size, unless tight shut-off is required.

3.4.5

Cage trims shall be specified for non-erosive liquid services with a high pressure drop to support the plug at the critical position.

3.4.6

One piece plug and stem construction is preferred. Where this is not possible, the plug/stem construction shall include a locking device to prevent accidental separation.

3.4.7

Seat rings shall be clamped or secured via a seat ring retainer. The welding of seat rings, shall require the approval of the Owner. The locking of seat rings with a fixing compound is not permitted.

3.4.8

Angle-body control valves should be used on hydrocarbon services where coke may be present, e.g. bitumen units, erosive services such as slurries, and any application where a solid contaminant may settle in the body of a glove valve.

3.4.9

Angle-body control valves may be considered for services which may have high noise levels or where cavitation may occur.

3.4.10

Packing glands shall be equipped with flange type gland followers secured by two bolts. A lubricator with a steel isolating valve shall be provided where packing lubrication is required.

3.4.11

Control valve bonnet and bottom flange shall be of bolted construction with fully retained gaskets.

GENERAL ENGINEERING SPECIFICATION CONTROL VALVES

GES J.06 Page 10 of 20 Rev 0 1999

3.5.1

Ball Valves, normally used for on/off service, may be considered for throttling services where a high flow co- efficient and rangeability is required. Ball valves in throttling service shall have a maximum ball rotation of

65°.

3.5.2

Ball valves used on throttling services, on/off valves where frequent operation occurs or where temperature and pressure fluctuations of the process fluid occurs shall have metal seats. Where particular matter is suspended or entrained in the process fluid and tight shut-off is required, scraper action with spring loaded seats shall be specified.

3.5.3

Soft seats may be specified for infrequent on/off operation on clean services, at temperatures below 250°F (120°C) and where the process temperature and pressure is considered to be constant.

3.5.4

Ball valves shall have a body rating conforming to the piping class, but shall be a minimum of ANSI Class 300 for sizes up to and including 16 inch. For larger sizes, ANSI Class 150 may be specified if this is in accordance with the piping class.

3.5.5

Ball valves used in modulating service shall have characterised ports or positioners.

3.6

Butterfly Valves

3.6.1

Where low pressure drop and/or high pressure recovery requirements indicate large globe valves, butterfly valves may be considered.

3.6.2

Butterfly valves shall be of the heavy duty wafer type with external roller bearings and lubricated packing.

3.6.3

The shaft and wafer shall be sized for a pressure drop equivalent to twice the maximum upstream pressure.

3.6.4

In throttling services, butterfly control valves shall have 100% C V with a 60° opening under maximum flow conditions. The use of special wafers allowing full control at higher angles of opening shall be subject to the Owner's approval.

3.7

Diaphragm Valves

3.7.1

Diaphragm (Saunders) control valves shall be considered for services such as slurry and chemical duty in water treatment plants, where the body lining of standard valves is not possible or is economically unattractive.

3.7.2

When applied for throttling service a characterising positioner may be necessary to obtain the necessary valve characteristic.

3.7.3

The diaphragm shall be selected to be suitable for the temperature pressure and chemical composition of the process fluid.

3.7.4

The diaphragm valve shall not be of the integral actuator type.

3.8

Cam-type Valves

Camflex or equivalent type valves may be used in place of globe valves where approved by the Owner.

3.9

Special Requirements for Valves in Oxygen Service

3.9.1

In liquid O 2 service, the body and trim materials shall be of ANSI Type 316 stainless steel. Bronze may be used for gaseous O 2 service.

GENERAL ENGINEERING SPECIFICATION CONTROL VALVES

GES J.06 Page 11 of 20 Rev 0 1999

3.9.3

Most materials used for soft seats can be hazardous when exposed to high velocity oxygen streams. Valves on throttling services should, therefore, not be specified with soft seats.

3.9.4

The valve bonnet shall not contain a lubricator nor a provision for one.

3.9.5

The Vendor/Contractor shall ensure that the valves are degreased, dried and sealed before transport.

3.9.6

All valves shall be certified by the Vendor as being suitable for oxygen service.

3.10

Spring Diaphragm Actuators

3.10.1

Control valve actuators shall preferably be of the spring-opposed, pneumatic diaphragm type.

3.10.2

The actuator instrument air supply shall normally be 3-15 psi (20-100 kPa) or 6-30 psi (40-200 kPa).

3.10.3

Actuator sizing shall permit full valve stroking against the maximum process differential pressure and spring tension at the rated air supply pressure.

3.10.4

Operation at other air pressures shall be subject to the approval of the Owner. Actuators requiring an air pressure in excess of 50 psig (330kPag) shall not be used.

3.10.5

The valve action shall be as defined on the data sheet but shall normally be to close on air failure, i.e. spring to close.

3.10.6

The valve Vendor/Contractor shall carry out actuator sizing calculations based on the information given in the data sheets, and shall submit the calculations to the Owner for approval.

3.10.7

In the absence of other stated requirements in the data sheets, the maximum stroking time for modulating control valves shall be 10 sec or less for valves up to 4 inch, and 15 sec for valves larger than 4 inch. Valves forming part of a surge control system shall have a stroking time of less than 5 sec.

3.10.8

The effect of stroking times on liquid filled lines should be checked for hydraulic shock or water hammer by the Vendor/Contractor.

3.10.9

The Vendor/Contractor shall state both the opening and closing stroking times.

3.10.10

Actuators connections to the valve stem shall be adjustable with positive locking.

3.10.11

Actuator linkage to rotary valves shall not use cams or gears.

3.10.12

The actuator shall have a travel limit stop in the open direction, set to be engaged before the valve plug reaches its travel limit.

3.11

Piston Actuators

3.11.1

Piston type actuators shall only be used where the required shaft thrust is in excess of that obtainable from diaphragm type actuators, or where they are an integral part of the valve design.

3.11.2

Short stroke spring opposed piston actuators shall be specified where possible.

3.11.3

Where long stroke springless actuators are required, attention shall be paid to methods of achieving the required action on air failure using lock-up valves or a secure air system.

3.11.4

The secure air system shall maintain sufficient pressure for at least 30 minutes or 3 full valves strokes.

GENERAL ENGINEERING SPECIFICATION CONTROL VALVES

GES J.06 Page 12 of 20 Rev 0 1999

3.11.6

Piston actuators shall be designed for low shaft and piston friction.

3.12

Valve Positioners

3.12.1

Control valve positioners shall normally be fitted to control valves on modulating services, unless a system analysis clearly indicates that a positioner is not required. The positioners shall normally be suitable for input signals of 3-15 psi (20-100 kPa) or 4-20 mA. The use of valve positioners accepting digital input signals, e.g. Hart or Fieldbus, shall require the approval of the Owner.

3.12.2

Control valve positioners shall be direct acting.

3.12.3

The positioner loop gain shall be between 50 and 100.

3.12.4

Where the positioner control signal input is pneumatic and of the same range as the valve input signal, a positioner bypass may be included to allow servicing of the positioner without taking the valve out of service.

3.12.5

Control valve positioners shall include gauges indicating the supply and output air pressures. Pneumatic positioners shall include an additional gauge indicating the control air signal.

3.12.6

Electronic control valve positioners, if approved by the Owner, shall be certified for use in accordance with the area classification.

3.12.7

The positioner casing shall give protection to IP 65 in accordance with IEC 60529.

3.13

Limit Switches

3.13.1

Open and/or close limit switches shall be provided as indicated on the Data Sheets.

3.13.2

Limit switches shall be directly actuated by the valve actuator stem without external linkages.

3.13.3

Proximity switches or proximitors shall be mounted inside a box for mechanical protection.

3.14

Limit Stops

3.14.1

Limit stops, which prevent the valve fully opening or closing, shall be provided only when indicated on Data Sheets.

3.14.2

Limit stops shall be mechanical devices mounted on the actuator, they shall not form part of the handwheel mechanism. Pneumatic limit stops may only be applied with the approval of the Owner.

3.14.3

Limit stops shall be adjustable over the specified range and be fitted with a tamper proof locking facility.

3.15

Volume Boosters

3.15.1

Volume boosters shall be used where it is required that a valve achieve a short stroking time in both directions.

3.15.2

Volume boosters for pneumatic actuators shall be of the high capacity type with fast throttling facilities to control the required capacity.

3.15.3

Volume boosters shall be installed on the actuator.

3.16

Handwheel

3.16.1

Handwheel shall be provided when shown on the Data Sheets.

GENERAL ENGINEERING SPECIFICATION CONTROL VALVES

GES J.06 Page 13 of 20 Rev 0 1999

side mounted and provided with position indication. The neutral position shall be clearly indicated.

3.16.3

The handwheel shall generally be of the non-declutchable type.

3.15.4

Handwheels shall not be fitted to emergency shut-off valves.

3.16.5

Re-orientation of the handwheel should be possible with the valve in-situ and without the use of additional components.

4.0

MATERIALS

4.1

Valve Body

4.1.1

Valve bodies shall be carbon steel unless process conditions require the use of other materials.

4.1.2

Carbon steel bodies shall be specified to ATM A 216 WCB to allow for possible repair welding.

4.1.3

Cast iron valve bodies shall not be permitted.

4.1.4

Austenitic, Monel and other nickel alloy valves shall have the trim and bolting of the same or similar materials as the body, unless otherwise specified.

4.2

Valve Trim

4.2.1

The control valve trim (plug, seat rings and stem), shall be of AISI 316 stainless steel, unless the process conditions require the use of other materials. The valve plug, whether of single or double seat construction, shall be machined from single bar stock or casting.

4.2.2

Hardened (stellited) plug and seat rings shall be selected for erosive services, wet gas or wet steam service with a pressure drop greater than 75 psi (500 kPa) and services where the pressure drops exceed 150 psi (1 MPa).

4.2.3

Small size valves shall have plugs and seat rings from solid stellite.

4.2.4

Stem guide bushing material shall be to the Vendor's standards, unless other materials are specified for the process conditions. The hardness of the stem guide bushing shall be at least 125 HB less than that for the valve stem. On erosive services, the bushing shall be at least 125 HB more than the stem.

4.2.5

Angle-body control valves for erosive services shall be supplied with a chrome plated venturi seat ring.

4.3

Gaskets and Packing

4.3.1

Teflon packing or carbon rings shall be used wherever possible. Asbestos packing shall be avoided and shall only be used above 450°F (230°C).

4.3.2

Butterfly and ball valves shall have "O" ring sealing of the shaft. The "O" ring material shall be `viton', unless process conditions dictate the use of other materials.

4.3.3

Gaskets for top and/or bottom flanges shall be to the line specification.

4.4

Actuator

GENERAL ENGINEERING SPECIFICATION CONTROL VALVES

GES J.06 Page 14 of 20 Rev 0 1999

4.4.2

Diaphragm cases shall be of pressed steel and of the multiple bolt type.

4.4.3

The diaphragm material shall be nylon reinforced neoprene, Buna N rubber, or equivalent.

4.4.4

The yoke shall be high-tensile strength cast or ductile iron as a minimum. The yoke shall be of the open type to allow access.

4.4.5

Actuator springs shall be of carbon steel and permanently treated to prevent corrosion. Cadmium plating is not permitted.

4.4.6

Fire safe actuators shall operate satisfactorily from ambient up to 300°F (150 °C), and shall remain functional for 15 minutes when exposed to a temperature of 2030°F (1110°C).

4.5

Sour Environments (NACE requirement)

4.5.1

All carbon and low alloy steel material used in sour service shall comply with, but not be limited to the requirements of NACE Standard MR-01-75.

4.5.2

The use of special corrosion resistant materials shall be subject to approval by the Owner.

4.5.3

All fittings and flanges shall be permanently identified using an acceptable method per NACE Standard MR- 01-75, or any other method acceptable to the Owner.

4.5.4

All sour service control valves shall be of the manufacturer's standard pattern with the trim and metallurgy selected to give corrosion and stress cracking protection. As a minimum all valves shall meet the requirements of NACE Standard MR-01-75.

4.5.5

"O" rings shall be manufactured from Teflon or Viton-A.

4.5.6

No threaded connections shall be permitted in sour gas piping.

4.6

Material Certification

Material certification shall be in accordance or better than the requirements of the relevant piping specification. Material test certificates shall be supplied with the equipment.

5.0

MANUFACTURE

5.1

QA/QC

The Vendor/Contractor shall submit to the Owner, for approval, details of his proposed quality assurance and quality control plan.

5.2

Valve Body

5.2.1

The valve body including bonnet and top or bottom flanges and external bolts or studs and nuts, etc., shall be equal or superior to the requirements of the piping class of the associated piping or vessels.

5.2.2

Gaskets for top and bottom flanges shall conform to the piping specification.

GENERAL ENGINEERING SPECIFICATION CONTROL VALVES

GES J.06 Page 15 of 20 Rev 0 1999

6.0

INSTALLATION

6.1

Block and Bypass Valves and Manifolds

6.1.1

Control Valves shall be provided with isolating block valves and a bypass valve as indicated on the P&ID.

6.1.2

Block and bypass valves shall be gate valves. Bypass valves less than 4 inch shall be globe valves.

6.1.3

Block valves shall normally be line size, but where the control valve is smaller than the line size, the block valve may be one line size smaller than the line size.

6.1.4

The bypass valve and piping shall be the same size as the control valve.

6.1.5

Bleed valves shall normally be located between the upstream block valve and the control valve.

6.1.6

Double block and bleed valves shall be used where the positive isolation of the control valve is required.

6.1.7

The materials and ratings for block and bypass valves shall conform to the piping specification.

6.1.8

The control valve manifold shall be designed so that the assembly is self-supporting on removal of the control valve.

6.2

Valve Location

6.2.1

Valves shall be located for easy access for operation and maintenance.

6.2.2

Permanent access ladders and platforms shall be provided where the valve is not at grade level, such that the valve is not higher than 5 ft (1.6 metres) above the access point.

6.2.3

Suitable access for lifting equipment, must be allowed where this is required.

6.2.4

The location of a handwheel or actuator shall not obstruct walkways or platforms.

6.2.5

Adequate clearance shall be allowed between bottom flanged valves and the grade or platform.

6.3

Pre-commissioning

6.3.1

A complete check of the control valve documentation shall be carried out before the control valve is installed. The check shall include all test documentation, materials certification and hazardous area certification.

6.3.2

Control valves shall not be installed until line hydrotesting and flushing is complete.

6.3.3

Control valves stored on site awaiting installation shall be kept in their original packing, in dry conditions, and where damage will not occur.

6.3.4

Check the control valve for proper flow orientation against the body flow markings.

6.3.5

The control valve interior shall be inspected through the end ports to ensure that it is reasonably clean and free from foreign matter and harmful corrosion. Ensure that all packing or shipping materials have been removed.

6.3.6

If possible, the control valve should be cycled by hand and functionally significant features e.g guides or seat faces be checked.

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7.1

Procedures

7.1.1

The inspection requirements are covered by the "General Conditions of Purchase" which forms part of the Purchase Order/Contract. Additional requirements are given below.

7.1.2

The Vendor/Contractor shall allow the Inspector free access to all areas of manufacture, fabrication, assembly and testing.

7.1.3

The Vendor/Contractor always has the responsibility to provide adequate quality control and inspection of equipment and materials. Any inspection by the Owner or his Inspector shall not relieve the Vendor/Contractor of these responsibilities or those under his warrantes.

7.2

Scope

The face to face dimensions of flanged valves shall be checked for conformance to ANSI/ISA S75.03. Other dimensions, including overall height, shall be checked against the Vendor/Contractor's approved drawings. The flange face finish shall be checked by visual and tactile comparison against test specimens conforming to the required specification.

7.3

Nameplates

7.3.1

A corrosion-resistant identification plate shall be fixed by means of rivets or screws to the valves. The plate shall, as a minium, carry the following information:

- the Vendor's/Contractor's name or trade mark;

- the valve and actuator model/type number;

- the Vendor's/Contractor's serial number;

- the body rating;

- the size of body and trim;

- the material of the parts exposed to the process fluid;

- the trim characteristics;

- the actual Cv value;

- the spring range;

- action on air supply and/or signal failure;

- the actuator size;

- the stem packing material.

7.3.2

A stainless steel tag containing the valve tag number shall be attached to the valve by a stainless steel wire.

7.4

Marking

7.4.1

The direction of flow and where applicable the tight shut-off direction shall be cast or stamped on the valve body.

7.4.2

The body shall be marked with the relevant material standard.

8.0

TESTING

8.1

Statutory Tests

Control valves shall be subjected to the factory tests detailed in this section. The Owner, or his appointed representative, may, at his discretion, witness all or part of the factory tests. The tests results shall in any case be made available to the Owner.

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8.2

Test Procedures

8.2.1

The Vendor/Contractor shall submit his test procedures in writing to the Owner for approval, prior to the start of the testing programme.

8.2.2

The pressure tests shall be carried out in the presence of Inspector(s) from the Owner's Inspection Authority.

8.2.3

For the hysterisis, deadband and stroking time tests, the valve shall be fully assembled and fitted with all accessories for the test.

8.3

Test Certificates

In addition to the Test Reports and letters of conformity, the following certificates shall be provided with each valve as minimum:

- Inspection Release Certificate;

- Code Compliance Certificate;

- Type Test Certificate;

- Hydrostatic Certificate;

8.4

Hydrostatic Tests

8.4.1

The control valves shall be hydrostatically tested in accordance with the requirements of ANSI B16.34, Section 7.0.

8.4.2

Clean potable water shall be used for testing carbon steel valves and demineralised water for stainless steel valves.

8.4.3

No visible leakage through the stuffing box shall be allowed.

8.5

Seat Leakage Tests

8.5.1

A seat leakage test shall be carried out on all valves where a seal leakage classification is specified. The test procedures shall be in accordance with IEC 534 Part 4 or ANSI/FCI 70.2.

8.5.2

The valve stem torque to close the valve shall be equal to that applied by the actuator with a signal equal to that normally necessary to close the valve.

8.5.3

The Vendor/Contractor shall state for each valve:

- the flow direction;

- the test medium;

- the valve differential pressure;

- the duration of the test;

- the measured and allowable seat leakage;

- the seat leakage classification.

8.6

Hysterisis Test

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8.6.2

The test shall be measured by taking the valve stem position with the following sequence of input signals 50%, 75%, 100%, 75%, 50%, 25%, 0% 25% and 50% approximately.

8.6.3

The hysterisis shall be no greater than 0.5% of the valve stroke.

8.7

Deadband Test

8.7.1

Dry air or nitrogen shall be used as the actuating medium.

8.7.2

The deadband is measured as the change in input signal necessary to produce a detectable movement of the

valve stem.

The deadband shall be measured with input signals of approx 5%, 50% and 95% of the input

span.

8.7.3

The deadband shall not exceed 1% of the input signal.

8.8

Stroking Time

8.8.1

Dry air or nitrogen shall be used as the actuating medium.

8.8.2

The stroking times shall be the time taken for the valve to travel from fully open to fully closed and return, following a step change in input signal equal to the input span.

8.9

Capacity Test

8.9.1

A capacity test shall be carried out for all valves at the Owner's request.

8.9.2

The actual C V shall be determined in accordance with ANSI/ISA S75.02.

9.0

DOCUMENTATION

9.1

Introduction

This section covers the documentation required for the design, fabrication, inspection, selection, fabrication and testing for all control valves and accessories.

The detailed list of documents that are required will be attached to the Purchase Order/Contract. However, as a minimum the following listed documents shall be provided by the Vendor/Contractor:

- Maintenance Manual.

- Certified Drawings showing valve dimensions and stating weights.

- Materials and Test Certificates.

- Valve sizing and Actuator force calculations.

- Shipping Conditions.

- Certificates covering the use of electrical equipment in hazardous (classified) areas.

- Results of testing.

- Electrical connection drawings.

9.2

Schedules and Reports

The Vendor/Contractor shall submit with his tender a preliminary quality control plan. The Vendor/Contractor shall supply a schedule showing the documents for review and approval, proposed sub-contractors and material procurement, and a production/ fabrication programme.

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The Vendor/Contractor shall submit all calculations and data for acceptance by the Owner within the period specified by the Purchase Order/Contract. The calculations and data shall become the property of the Owner after acceptance.

9.4

Drawings

The drawings listed with the Purchase Order/Contract shall be sent by the Vendor/Contractor to the Owner and/or Inspection Authority for review and approval.

9.5

Final Records, Documents and Manuals

Two copies of the Data book and six copies of the Installation/operating/maintenance manual shall be supplied with the equipment.

10.0

PRIOR TO SHIPMENT

10.1

Painting and Coatings

10.1.1

Painting of Control Valves shall be in accordance with NOC Specification GES X.06.

10.1.2

Painting and protective coatings shall take into account the methods of transport to be used (e.g. deck cargo).

10.1.3

The Vendor/Contractor's standard painting and coating systems may be acceptable, subject to Owner's approval, provided they are equal to or better than the Owner's standards specified in GES X.06 and are equally suitable for the site environmental conditions specified in GES A.06.

10.2

Spares

The Vendor/Contractor shall submit with his proposal, a priced list of recommended spares for start-up and two years operation.

10.3

Packing and Storage

10.3.1

This section describes the minimum requirement for the preservation and protection of control valves and accessories during sea and land transportation and storage.

10.3.2

The probable storage period will be specified in the Purchase Order/Contract and will extend from the time of despatch to the time of unpacking at site. If the storage period is not stated, a minimum period of 24 months shall be assumed.

10.3.3

All control valves and accessories shall be securely packaged and protected against external damage.

10.3.4

Machined or threaded exterior surfaces shall be protected during shipment and subsequent storage with a rust preventative which is easily removed with a petroleum solvent.

10.3.5

Threaded end or socket welding connections shall be fitted with metal, wood or plastic plugs or caps.

10.3.6

Flanges shall be protected over the entire flange surface by 0.5 in thick plywood covers, bolted and sealed to prevent the ingress of dirt, dust and water.

10.3.7

After final acceptance, valve bodies shall be thoroughly cleaned, internally and externally, of all foreign matter, and dried.

10.4

Shipping

The control valves and accessories shall not leave the Vendor/Contractor's works for shipment until the release has been approved by the Owner's Inspector.

10.5

Warranty

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The Vendor/Contractor shall warrant all materials and services under the Purchase Order against any defect, for a minimum period of 12 months after commissioning, or 24 months from the date of delivery to the stipulated point of delivery, whichever is the shorter period, or such period as may be expressly stated in the Purchase Order/Contract.

The Vendor/Contractor shall be responsible for all costs associated with restoring the equipment to a standard equivalent to that specified in the Purchase Order/Contract.

The Vendor/Contractor shall undertake to carry out the repair or replacement in an expeditious manner.

The terms and conditions of the Warranty shall be additional to any other requirements specified in the Purchase Order.