Technical Requirements For Valves PDF

MUMBAI INDIA TECHNICAL REQUIREMENTS FOR DOC. NO.
TOYO ENGINEERING INDIA LTD. PIPING MATERIALS 6249-A-00-481
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ISSUE DATE 25-JAN-08 21-OCT-08 PAGE 13 OF 44
ANNEXURE - A1
TECHNICAL REQUIREMENTS
FOR VALVES
© TOYO ENGINEERING INDIA LTD

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1.0 GENERAL
1.1 Vendor shall supply valves in accordance with the valve specification sheets along with
auxiliaries, if any, such as gear operator, bypasses, drains etc.Whenever specified in the
specification sheets, subject notes and other enclosures to the material requisition (MR).
1.2 Vendor shall quote in strict accordance with the valve data / specification sheets, subject
technical notes and all other enclosures to the MR. Deviations to the specification / data
sheets, subject technical notes and other enclosures of the MR, if any, shall be asked as
explained in clause 2.0.
1.3 All codes and standards for manufacture, testing, inspection etc. shall be of latest editions.
1.4 Exceptions or variations covered in project specific requirements by Licensor / Owner / PMC
which are superior to the requirements covered herein shall take precedence.
2.0 DESIGN AND CONSTRUCTION
2.1 Valve shall be designed, manufactured, tested, inspected and marked as per the
manufacturing standards; design codes and standards (latest editions) indicated in the
respective valve specification sheets. Any conflict between the requisition, enclosures,
specification sheets and referred standard codes shall be brought to the noticed of the
purchaser for clarifications. But generally, specification sheets and enclosure of the
requisition including subject notes shall govern. After issue of the purchase requisition (PR),
no deviation to specification / standards shall be permitted through vendor drawing approval.
Approval of drawings shall be valid only for design / constructional features.
2.2 Valves of Class 900 & above shall be pressure-seal type. Threaded and seal welded or
welded bonnet may be employed up to sizes 1.1/2”.
2.3 All flanged valves (except forged) shall have flanges integral with the valve body.
Weld on flanges shall be made full penetration joints and 100% radio graphed.
2.4 Valve Castings/Forgings purchased from India or Indian vendors shall be from PMC
approved foundries/ forging shop.
2.5 Yoke material shall be at least equal to body material.
2.6 Forgings are acceptable in place of casting but not vice versa.
2.7 No cast iron valves to be used in firewater or any other service except in drinking water
service.
2.8 Valve under cryogenic service (temp. below -45 Deg.) shall meet the requirements of BS-
6364 and shall be procured from pre qualified vendor.
2.9 Unless otherwise specified, valve stem packing shall be grafoil die moulded rings / or equal for
piping class above -290C & Grafoil die moulded rings for piping classes with temperature
below -290C. Whenever Grafoil die moulded rings are specified / used for valve packing, stem

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finish shall be 32 RMS. Selection of valve stem packing shall be reviewed for intended service
condition (i.e. temperature, fluid used etc.).
2.10 Stem shall be forged or machined from forged / rolled bar. No casting is permitted. However,
integral stem of cast stainless steel ball valve is acceptable.
2.11 Stelliting / hard facing by deposition shall be minimum 1.6mm. Renewable seat rings shall be
seal welded.
2.12. Flange face finish shall be normally specified in the valve specification sheet as serrated
finish, 125 AARH etc. The interpretation for range of face finish shall be as follows:
Stock Finish - 1000 µ in AARH max. (For Lap joint flanges)

Serrated finish
Serrations with 125 to 250 µ in
/Smooth - (For RF & FF flanges)
AARH
Finish/125AARH
Extra Smooth
- 32 TO 63 µ in AARH (For RTJ Flanges)
Finish/63 AARH
2.13 For all weld end valves with bevel end as per ASME B16.25, the contour of bevel shall be as
follows
Material Wall Thickness Weld Contour

Carbon Steel (Except Low Temp. Up to 22 mm Figure 2 Type A
Carbon Steel) > 22 mm Figure 3 Type A
Up to 10 mm Figure 4
Alloy Steel, Stainless Steel &
> 10 mm & Up to 25 mm Figure 5 Type A
Low Temp. Carbon Steel
> 25 mm Figure 6 Type A
2.14. For flanged valves with Ring Joint Flanges the groove hardness shall be as follow:
Flange Material Min. hardness of Groove (BHN)

Carbon Steel 140
1% Cr. To 5% Cr. 150
Type 304, 316, 347, 321 160
Type 304 L, 316 L 140
2.15 DIMENSIONS
2.15.1 Face-to-Face/End-to-End dimension shall be as per ANSI B16.10. In case the same is
not covered under B16.10, the dimension shall be made to respective valve design
standard / BS 2080 and / or the Manufacturer’s Std.
2.15.2 Flange dimensions of C.S Alloy Steel and Stainless Steel valves shall conform to the
respective flange standard specified in the piping class.

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2.16 Pressure – temperature rating for flanged and butt welding end valves shall be as per ANSI
B16.34 except for ball, plug & butterfly valves. Wall thickness of the body at different
locations should not be less than as calculated as per respective valve standards. For ball,
plug, and butterfly valve manufacture’s recommendations shall be obtained before use for
intended service.
Unless called –out specifically, valves shall be as per the following standards:
VALVE SIZE RATING DESIGN STD. TESTING STD.

Gate 1/2” – 1.1/2” 800 /1500 API-602 API-598
Globe / check 1/2” – 1.1/2” 800 /1500 BS EN ISO 15761 BS EN 12266-1/2
Gate / globe / API-598 /
1/2” – 1.1/2” 2500 B-16.34
check BS EN 12266-1/2
Gate 2” – 24” 150/300/600 API 600 API 598
Gate 26”- 42” 150/300 BS-1414 BS EN 12266-1/2
Globe 2”-12” 150/300/600 BS-1873 BS EN 12266-1/2
Check 2” – 24” 150/300/600 BS-1868 BS EN 12266-1/2
Dual Plate API-594
26”-48” 150/300 API-598
Check (Double flanged )
Gate 2” – 24” 900/1500/2500 API-600 API-598
Globe 2” - 24” 900/1500/2500 BS-1873 BS EN 12266-1/2
Check 2” - 24” 900/1500/2500 BS-1868 BS EN 12266-1/2
Ball 1/2” -16” 150/300/600 BS EN ISO 17292 BS EN 12266-1/2
Ball 2” -16” 900/2500 API-6D BS EN 12266-1/2
API-598 /
Plug 1/2” -12” ALL API 599 / BS-5353
BS EN 12266-1/2
API-598 /
API 609 / BS-5155
Butterfly 3” & above ALL BS EN 12266-1/2 /
/ AWWA C504
AWWA
Diaphragm ALL - BS-5156 BS EN 12266-1/2
RELEVANT IS RELEVANT IS
Bronze
STD. STD.
RELEVENT IS RELEVENT IS
Cast Iron
STD. STD.
If not covered in above table, the valve shall be as per ASME B16.34 /relevant MSS-SP.
standard.
2.17 Following requirements for check valves shall be met over and above the valve spec sheet
requirements:
1. Unless specified otherwise in the data sheet all swing check valves 3” & above
(except in 900#, 1500# & 2500# rating) shall have a drain boss at location “G” (refer

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fig. no. 1 of ASME B 16.34). A tapped drain hole with plug shall be provided as per
ASME B 16.34. Threads shall be as per ASME B1.20.1 (Taper) NPT.
2. Wherever check valve disc assembly is supported from the cover of the check valves
the following shall be ascertained.
a) Positive location / positioning of cover must be provided to ensure correct

alignment of the valve disc.
b) Hinge pin design must permit accurate alignment of the disc and valve seat.
3. For heavy check valves, provisions shall be available for lifting by way of lugs, eye
bolts and other such standard devices.
2.18 If any overlay weld-deposit is used for the body seat ring seating surface, the corrosion
resistance of the seat ring base material shall be at least equal to the corrosion resistance of the
material of the shell.
2.19 Following valve bypass requirements shall be met:
2.19.1 By-pass requirement for Gate valves is indicated in the respective data sheets. As a
rule, the following shall be followed :
Class For sizes

ASME 150 CLASS 26” and above
2.19.2 The by-pass piping arrangement shall be such that clearance between main valve body
and by-pass assembly shall be minimum possible for layout reasons. Vendor shall
follow the sketch enclosed in Annexure-A2.
2.19.3 By-pass piping and valve shall be compatible material and design. Complete fillet
welds for by-pass installation shall be DP/MP tested. NDT of by-pass valve shall be
inline with main valve.
2.19.4 By-pass valve shall be a globe valve. The sizes shall be as under:
On main valve ≤ 4” 1/2 “ or more

On main valve > 4” but < 10” 3/4 “ or more
On main valve ≥ 10” 1” or more
The by-pass piping, fittings and valve tag numbers shall be as specified in Annexure A2
2.19.5 Vendor shall supply the by-pass valve duly tested and fitted to the main valve. Valves
with by-pass shall have the direction of flow marked on the main valve. By pass

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attachment to the main valve body shall not be screwed. All fillet welds for by-pass
installation shall be 100% examined by DP/MP test.
2.20 Valve body / bonnet shall be forged / cast as specified. Forging are acceptable in place of
casting but not vice-versa.
2.21 Material of construction of yoke shall be minimum equivalent to body / bonnet material.
2.22 For all Austenitic Stainless steel valves, Inter Granular Corrosion (IGC) Test shall be
conducted as per following:
2.22.1 ASTM A262 Practice ‘B” with acceptance criteria of “60-mils/year (max.)”.
OR
ASTM A262 Practice ‘E’ with acceptance criteria of “No cracks as observed from
20X magnification & Microscopic structure to be observed from 250X magnification”
2.22.2 For IGC test as described in Clauses 2.22.1 two sets of samples shall be drawn from
each solution annealing lot. One set shall correspond to the highest Carbon content
and other to the highest pressure rating. When testing is conducted as per practice “E
“, photograph of the microscope structure shall be submitted for record.
2.23 All types of 321 or 347 stainless steel of valves shall be in a stabilized heat treated condition.
Stabilising heat treatment shall be carried out subsequent to normal solution annealing.
Soaking temperature and holding time for Stabilising heat treatment shall be 900 deg. C and 4
hrs. respectively.
2.24 Spiral wound bonnet gaskets are to be provided with inner / outer ring except when
encapsulated gasket type body-bonnet joints are employed. Outer ring may be avoided in case
of non-circular spiral wound gasket used in 150# valve provided the outermost layer of spiral
touches the bolts ascertaining the centering.
2.25 BALL /PLUG / BUTTERFLY VALVES :
2.25.1 As a prequalification, fire safe test as per API 607 / API 6FA / BS 6755 Part II
shall be carried out on soft seated ball, plug & butterfly valves and also on lubricated
plug valves. The test shall be witnessed and certified by third party inspection agency
like Lloyds, B.V., DNV or PMC for Indian vendors, inspection agency shall be PMC
only. The vendor has to submit test certificate for the particular design of the valve
offered.
2.25.2 Each valve shall be supplied with a lever/wrench except for gear operated/motor
operated valves.
2.25.3 Soft-seated Ball, Plug & Butterfly valves shall be supplied with antistatic devices.
2.25.4 Soft- seated BW /SW end ball valves shall have a 100 mm long seamless pipe nipple
welded to each end of the valve. Nipples are to be welded prior to assembling Teflon
seats / seals. Specifications of the nipples shall be indicated in the MR.

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2.25.5 The face-to-face dimensions of all ball valves shall be same as those of gate valves of
the corresponding ANSI class (except 10” onwards in class 150 where the face-to-
face dimensions shall be as per API 6D long patterns).
2.25.6 The ball of ball valve shall not protrude outside the end flanges of valve.
2.25.7 Ball valves shall be floating ball type / trunnion mounted type as per following:
Class Floating Ball Trunnion Mounted

150 # 8” & below 10” & above
300# 4” & below 6” & above
600# & above 1.1/2 & below 2” & above
2.25.8 Unless otherwise specified in the data sheets, bore of the all reduced bore ball valves
shall be limited to one size lower than the nominal bore.
2.25.9 Butterfly valves if specified / used in other than cooling water lines (cat. ‘D’ services)
shall be high performance fire safe design to API-609.
2.25.10 Use of soft-seated ball/plug/butterfly valves shall be suitably selected based on

temperatures handled.
2.25.11 Butterfly valve shall be suited for throttling application.
2.25.12 Use of fire safe valves shall be as per process requirement.
2.25.13 For process (hydrocarbon) services butterfly valves shall be triple offset, high
performance type.
2.25.14 Stem of Ball, Plug, and Butterfly valve shall be Blow-out Proof.
2.25.15 Fire safe soft seated plug valves shall be tested and certified as only meeting the
external leakage requirements of API 607.
2.26 Ends of flanged valves of 22” size shall match corresponding flanges to MSS-SP44 unless
otherwise specified.
2.27 Unless otherwise noted, copper, brass or silver alloy are not permitted in contact with the
flowing medium in steel valves.
2.28 All forged chrome-moly valves shall be furnished in normalized and tempered condition in
accordance with ASTM A182M.
2.29 The term “Valve Trim“is defined as “All wetted internal parts of valve which come into the
rubbing action”.

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2.30 Plug valve and ball valve should be drilled to relieve pressure from the plug port area when
the valve is closed. Thermal expansion of liquids contained in the unrelieved and closed plug
and ball valve ports, as is possible on heat traced installations, can exceed the body rating of
the valve.
2.31 Whenever the term “STELLITE: is mentioned it mean facing of seat and disc or wedge by
Cobalt- Chromium – Tungsten alloy. Stelliting should be able to maintain hardness of
375BHN at high temperatures. Whenever the term “HARD” is mentioned with references to
seat or disc of valve, it should be 350-500BHN (min).
2.32 Orientation of valves stem below horizontal position shall be avoided.
2.33 Asbestos material shall not be used in body – bonnet / cover gasket & packing material.
2.34 For IBR service refer, Special Requirements for IBR Service, Annexure – A3.
2.35 For HYDROGEN services, refer Special Requirements for hydrogen Service, Annexure-F.
2.36 For low temperature services, refer Special Requirements for low temperature & cryogenic
valves, Annexure-G.
2.37 For vacuum services, refer Special Requirements for Vacuum service, Annexure-H.
2.38 For licensor’s special requirements refer, Annexure-K
3.0 OPERATION
3.1 Generally the valves are hand wheel or lever operated. Gear operation shall be provided as
under :
Valve Type Class Size requiring Gear-operator

150 CLASS 12” AND ABOVE
Gate / Globe & diaphragm 300 CLASS 12” AND ABOVE
valve 600 CLASS 12” AND ABOVE
Gate / Globe / Y-Globe / 1500 CLASS 3” AND ABOVE
Stop Check valve 2500 CLASS 3” AND ABOVE
Ball valve / plug valve (other
than pressure balance plug
valves)
Butterfly valve 150,300 CLASS 6” AND ABOVE
3.2 Hand wheel diameter shall not exceed 750 mm and lever length shall not exceed 500mm on
either side. Effort to operate shall not exceed 35 kg at hand wheel periphery. However,
failing to meet the above requirement, vendor shall offer gear operation.

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For sizes lower than these ranges, hand wheel / lever / wrench shall be provided. For
pressure balance plug valves manufacturer’s recommendation shall be acceptable provided
the requirements specified as above.
3.3 Gear operator shall be as under, with position indicators for open / close positions and with
limit stops.
(Limit stops are not applicable for gate and globe valves).
Totally enclosed bevel gear in grease case with

For Gate / Globe / Diaphragm valves
grease nipples / plugs
Totally enclosed helical worm or combination of
For Ball / Plug / Butterfly valves helical worm and spur gear in grease case with
grease nipples / plugs.
3.4 Where gear operator is not called for as per clause 3.1 but vendor recommends a gear
operator, he shall highlight such case (s).
3.5 Gear operator shall be so designed as to operate effectively with the differential pressure
across the closed valve equal to the cold non-shock pressure rating.
3.6 Ball, plug, butterfly valves, even with wrench or lever operators shall have ‘Open’ position
indicators with limit stops.
4.0 INSPECTION AND TESTING
4.1 Every valve shall be subjected to all the mandatory tests and checks called in the respective
codes / data sheet by PMC inspection or any third party as approved by the purchaser. For
IBR valves refer Annexure – A3
4.2 Every valve, its components and auxiliaries must be subjected to all the mandatory tests and
checks called for in the respective codes, data sheets etc. by the manufacturer.
4.3 Though the extent of inspection shall be as under, exact extent with hold points shall be
decided by PMC regional inspection office and recorded in the form of inspection plan. In
case of third party inspection, the inspection plan shall be approved by the purchaser.
Forged valves:
1. Visual and dimensional inspection

2. Review of material test certificates.
3. Any mandatory or supplementary test.
4. Hydrostatic test on 10% valves selected on random basis.
5. Strip check is required for 1% of total ordered quantity of valves (min. 1 NO.)
against valve use in following services:
Low Temp., Cryogenic, Hydrogen, Corrosive.

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Cast steel valves:
1. Visual and dimensional inspection.

2. Review of material test certificates.
3. Review of radiographs / radiographic reports or any other NDT tests wherever
applicable as per data sheet.
4. Any mandatory or supplementary test.
5. Hydrostatic test 100% for body, 10% other test.
6. Strip check is required for 1% of total ordered quantity of valves (min. 1 NO.)
against valve use in following services:
Low Temp., Cryogenic, Hydrogen, Corrosive.
4.4 In case of motor operated or actuator operated valves, functional / operational checks as per
the requirements of the specification shall be made on each valve.
4.5 Positive Material Identification (PMI) shall be performed as per the scope and procedure as
defined in the ‘specification for Positive Material Identification (PMI)’.
5.0 RADIOGRAPHY OF CAST VALVE
5.1 All casting shall be of radiographic quality. This requirement to be ensured by sample
radiography before proceeding with the actual production.
5.2 Radiography procedure, areas of casting to be radiographed, and the acceptance criteria
shall be as per ASME B16.34
a) Radiography requirement for casting of sizes for special /critical piping classes shall
be as follows:
1) For hydrogen / hydrogen bearing hydrocarbons, oxygen, NACE services &

stress relieved piping classes:
Class Size Qty.

150 # up to 24” 50%
300 # up to 16” 50%
2) For LT/CRYO services:
Class Size Qty.

150 # up to 24” 20%
300 # up to 16” 20%
3) For alloy steel and SS casting :
Class Size Qty.

150 # up to 24” 10%
300 # up to 16” 10%

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b) Radiography requirements for castings for categories not mentioned in a) above shall be
as follows :
Class Size Qty. Remarks

150 Up to 24” 5% For carbon steel material (except cat `D`
& fire water services for which it is NIL)
150 Up to 24” 10% For alloy steels & Stainless steel
150 26” & above 100% For all material (nil for cat D & fire water
service)
300 Up to 16” 10% For all material
300 18” & above 100% For all material
600 & above All 100% For all material
Note 1: No radiography is required for casting for Demineralized water service (Cat D)
Note 2: for stabilized grades of SS 100% radiography is required for castings irrespective
the category or rating this belongs to.
5.3 Radiography procedure, area of casting to be radiographed shall be as per ASME B16.34
and acceptance criteria shall be as per ASME B16.34 Annexure-B. However for areas of
casting to be radiographed for types of valves not covered in ASME B16.34, vendor shall
enclosed details of areas to be radiographed in line with ASME B16.34.
6.0 MARKING
6.1 Valve markings, symbols, abbreviations, etc. shall be in accordance with MSS-SP-25 or the
standard referred in specification sheet as applicable. Vendor’s name, valve rating, material
designation, nominal size, direction of flow (if any) etc shall be integral on the body.
6.2 Each valve shall have a corrosion resistant tag giving size, valve tag / code no., securely
attached to the valve body.
6.3 Paint or ink for marking shall not contain any harmful metal or metal salts such as zinc, lead
or copper which cause corrosion attack on heating.
6.4 Caron steel / Alloy Steel valves shall be painted with one coat of inorganic zinc silicate
(minimum DFT 65 to 75 microns).
7.0 DISPATCH
7.1 Valve shall be dry, clean and free from moisture, dirt and loose foreign materials of all kinds.
7.2 Valves shall be protected from rust, corrosion, and any mechanical damage during
transportation, shipment and storage.
7.3 Rust preventive on machined surfaces to be welded shall not be harmful to welding or shall be
easily removable with a petroleum solvent.

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7.4 Each end of valve shall be protected with the following materials :
Flange Face : Wood or Plastic Cover

Bevelled End : Wood or Plastic Cover
SW & SCRD end : Plastic Cap
7.5 End protectors of wood / plastic to be used on flange faces shall be attached by at least three
bolts and shall not be smaller than outside diameter of flange. However plastic caps for SW &
SCRD.end valves shall be press fit type.
7.6 End protectors to be used on beveled end shall be securely and tightly attached.
7.7 For special service valves additional requirement of dispatch shall be prescribed in data sheet.

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ANNEXURE - A2
BY-PASS ARRANGEMENT

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BY-PASS ARRANGEMENT
NOTES:
1. The orientation & location of hand wheel of bevel gear operator & the bypass arrangement
shall be strictly as per this sketch.
2. The bypass pipe ends shall be socket/butt welded to the body wall of the main valve.
3. The bypass arrangement shall be properly clamped to & supported by the body of the main
valve.
4. Basic design of bypass shall be to MSS-SP-45 & ASME B16.34.
5. Material of bypass pipe & 900 elbows shall be same or equivalent to the body material as
indicated in specification no.
6. This sketch is applicable for both BGO & NON-BGO valves.
7. Vendor shall furnish dimensions L1 to L8.

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SPECIFICATION FOR BYPASS PIPING, FITTINGS AND VALVES
CLASS (MAIN VALVE BY PASS VALVE SHT.

PIPE FITTINGS
SHT. NO.) NO.
A 106 GR.B (SEAMLESS)
A1A (51301) ASTM A105, SW CL.3000 52001
SCH XS
A2A (51302) ASTM A105, SW CL.3000 52002
SCH XS
IS 1239 (WELD)
A33A (51301) ASTM A105, SW CL.3000 52001
SCH HVY
D2A (51502) ASTM A105, SW CL.3000 52002
SCHXS
A 335 GR.P11 (SEAMLESS) ASTM A234GR.WP11CL.2,
G2D (51892) 52291
SCH XXS BW SCH XXS

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ANNEXURE - A3
SPECIAL REQUIREMENTS
FOR IBR SERVICE

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SPECIAL REQUIREMENTS FOR IBR SERVICE
1. For Steam condensate service under IBR:
A All item under the purview of `IBR’ (Indian Boiler Regulation) shall be
accompanied with IBR certificate original in From IIIA for pipes and IIIC for other
piping items duly approved by IBR Authority/Local Authority empowered by Central
Board of India.
Alternatively, photocopy of the original certificate duly countersigned and attested by
Local Boiler Inspection is the minimum requirement.
B. (l) For material 1¼ Cr-½ Mo (ASTM A335 Gr. P11/A691Gr.¼Cr)& 2¼ Cr-1Mo

(ASTM A335 Gr.P22/A691 Gr.2¼ Cr) from IIIA approved by IBR should include
the tabulation of Et, Sc and Sr values for the entire temperature range given below. Et,
Sc and Sr value shall be such that throughout the temperature range
Et/1.5 ≥
Sr/1.6 ≥ SA
Sc ≥
SA (PSI)
TEMP (˚F)
500 600 650 700 750 800 850 900 950 1000 1050 1100
MATERIALS
A335 Gr.P11 17200 16700 16200 15600 15200 15000 14500 12800 9300 6300 4200 2800
A691Gr.1¼Cr 18900 18300 18000 17600 17300 16800 16300 15000 9900 6300 4200 2800
A335 Gr.P22/
17900 17900 17900 17900 17900 17800 14500 12800 10800 7800 5100 3200
A691Gr.2¼Cr
NOTE: SA VALUES ARE FROM B31.3-2004, VALUES SHALL BE AS PER LATEST

EDITION PREVAILING.
B. (II) For material 1¼ Cr-½ Mo (ASTM A234 Gr. WP11 and ASTM A234Gr.WP11W) &
2¼ Cr-1Mo (ASTM A234 Gr.WP22 and ASTM A234 Gr.WP22W) from IIIC
approved by IBR should include the tabulation of Et, Sc and Sr values for the entire
temperature range given below. Et, Sc and Sr value shall be such that throughout the
temperature range.
Et/1.5 ≥
Sr/1.6 ≥ SA
Sc ≥

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SA (PSI)
TEMP (˚F)
500 600 650 700 750 800 850 900 950 1000 1050 1100
MATERIALS
A234Gr.WP11
CL.2 /
21700 20900 20500 20100 19700 19200 18700 13700 9300 6300 4200 2800
A234 Gr.WP11
CL.2W
A234Gr.WP22
CL.1 /
17900 17900 17900 17900 17900 17800 14500 12800 10800 7800 5100 3200
A234Gr.WP22
CL.1W

EDITION PREVAILING.
B. (III) For material 1¼ Cr-½ Mo (ASTM A182 Gr. F11)& 2¼ Cr-1Mo (ASTM A182
Gr.F22) from IIIC approved by IBR should include the tabulation of Et, Sc and Sr
values for the entire temperature range given below. Et, Sc and Sr value shall be such
that throughout the temperature range
Et/1.5 ≥
Sr/1.6 ≥ SA
Sc ≥
SA (PSI)
TEMP (˚F)
500 600 650 700 750 800 850 900 950 1000 1050 1100
MATERIALS
A182Gr.
21700 20900 20500 20100 19700 19200 18700 13700 9300 6300 4200 2800
F11 CL.2
A182Gr.
17900 17900 17900 17900 17900 17800 14500 12800 10800 7800 5100 3200
F22 CL.1

EDITION PREVAILING.
C. In carbon steel piping carbon content shall not exceed 0.25% for all pipe, fittings,
flanges & valve bodies etc. that may require welding. Moreover, for flanges the
sulphur and phosphorus also shall be limited to 0.05%each.
However other chemical compositions shall be as per IBR regulation.
For carbon steel materials, maximum carbon equivalent (CE) shall be 0.43 wt%
Where CE = %C + %Mn/6 + (%Ni + %Cu)/15 + (%Cr + %Mo + %V)/5

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Pipe material shall be as follows: (Unless specified otherwise)
Up to 14” : ASTM A 106 Gr. B (SMLS)

16” and above : ASTM A 672 Gr.B60, CL.12 / 22 / 21
D. All “IBR” valves shall be painted red in body-bonnet / body- cover joint.

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ANNEXURE - F
FOR HYDROGEN SERVICE

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SPECIAL REQUIREMENTS FOR HYDROGEN SERVICE
1.0 GENERAL
These requirements are applicable in addition to the requirements specified in the Piping
Material Specification.
2.0 PIPES, FLANGES AND FITTINGS
2.1 METHOD OF MANUFACTURE
All carbon steel pipes, fittings & flanges having wall thickness 9.53 mm and above shall be
normalized. Cold drawn pipes & fittings shall be normalized after the final cold draw pass for
all thickness. In addition, fittings made from forgings shall have carbon - 0.35% maximum
and silicon -0.35% maximum. The normalizing heat treatment shall be a separate heating
operation & not a part of the hot forming operation. All welded CS pipes shall be stress
relieved.
All alloy steel (Cr-Mo) pipes, forgings & fittings shall be normalized and tempered. The
normalizing and tempering shall be a separate heating operation and not a part of the hot
forming operation. The maximum room temperature tensile strength shall be 100,000 psi.
2.2 POST WELD HEAT TREATMENT (PWHT)
All carbon steel pipes & fittings having wall thickness 19mm and above shall be post weld
heat-treated.
All alloy steel (Cr-Mo) pipes & fittings shall be post weld heat treated irrespective of type or
thickness of weld.100% radiography of welded joints shall be done both before and after
PWHT.
All austenitic SS grades shall be solution annealed after welding.
2.3 FERRITE NO. TEST
For all austenitic stainless steels, the weld deposit shall be checked for ferrite content. A
Ferrite No. (FN) not less than 3% and not more than 10% is required to avoid sigma phase
embitterment during heat treatment. FN shall be determined by Ferrite scope prior to post
weld heat treatment.
2.4 IMPACT TEST
For carbon steel and alloy steels pipes, fittings & flanges of thickness over 19mm, Charpy-V
notch impact testing shall be carried out in accordance with paragraph UG-84 of ASME
Section VIII, Div-1 for weld metal and base metal from the thickest item per heat of material
and per heat treating batch. Impact test specimen shall be in complete heat treated condition
and in accordance with ASTM A370. Impact energies at 00C shall average greater than 27J
(20 ft-lb) per set of three specimens, with a minimum of 19J (15 ft-lb).

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If welding is used in manufacturing, impact test of Heat Affected Zone (HAZ) and weld metal
shall also be carried out.
2.5 HARDNESS
For carbon steel pipes & fittings, hardness of weld and HAZ shall be limited to 200 BHN
(max.).
For alloy steel pipes & fittings, hardness of weld and HAZ shall be limited to 225 BHN
(max.).
2.6 RADIOGRAPHY
All girth welded joints (longitudinal & circumferential) shall be 100% radiographed in
accordance with UW-51 of ASME Section VIII, Div-1 and ASME Section V.
3.0 VALVES
3.1 All valve castings shall be of radiographic quality.
3.2 All cast valve flanges and bodies of rating 900# or greater shall be examined in accordance
with paragraph 7.2 through 7.5 of Appendix 7of ASME Section VIII, Div-1, regardless of
casting quality factor.
3.3 only normalized and tempered material shall be used in the following specifications:
A217Gr.WC1, A217Gr.WC4, A217Gr.WC5, A217Gr.WC6, A217Gr.WC9,

Casting :
A217Gr.C5, A217Gr.C12.
Forging : A182 Gr.F11 CL.2, A182 Gr.F22 CL.3, A182 Gr.F5, A182 Gr.F9
3.4 Body/ bonnet/ cover joints & stuffing box of valves shall have low emission. One valve per
size / per valve sheet number shall be helium leak tested as per ASME Section V, Subsection
A, article 10 (Detector probe technique), Appendix IV at a minimum of 25% of the allowable
(rated) cold working pressure. Selection of valves for helium leak test shall be at random. Test
duration shall be as follows:-
Test Duration in minutes

Pressure class
Nominal size
Up to 300 600 800 & 900 1500 2500
Up to 2” 3 6 9 12 12
3” to 6” 6 9 12 15 18
8” to 16” 9 9 12 15 18
18” to 24” 9 12 15 18 21
The valve shall show no leakage. No leakage is defined as total leakage rate of less than
0.0001 ml/s of helium.

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3.5 C.S. & A.S. VALVES
Bend test and magnetic particle inspection of the entire surface of body and bonnet casting
shall be in accordance with ASTM A217. Supplementary requirement S3 & S4 evaluation of
magnetic particle inspection shall be in accordance with MSS-SP-53 except that no linear
discontinuities shall be allowed.
The Brinell hardness of heat-treated casting shall not exceed 200 BHN for carbon steel & 225
for alloy steel.
Repair of defective casting shall be outlined in writing to the purchaser before commencing
repair. Repair method to be approved prior to welding.
Carbon steel shall be normalized and alloy steel shall be normalized and tempered.
Casting shall be preheated to a minimum of 400ºF prior to welding and all chromium
molybdenum alloys shall be post weld heat treated after welding is complete. Stress relieving
is essential for welds.
Dye penetrant test of welds shall be in accordance with ASTM B16.5 Procedure B-2.
interpretation as per Appendix-8 of ASME-VIII Div.1.
The tensile stress for AS shall be less than 100,000 psi.
Charpy V-notch impact testing is to be done for valve material (average 20 ft-lb for set of 3
(min. value 15 ft-lb) at 300F ).
For radiography and acceptance criteria for valve casting refer Clause 3.6, Para. no.2.
3.6 S. S. VALVES
Casting and test bar shall be heat treated together. Valve casting shall be in the solution heat
treated and pickled condition.
Critical body and bonnet casing section typically defined by ASME B16.34 shall be
radiographed and shall meet the requirement of ASTM E446 (up to 2” thick) category A, B &
CA Level 2, category CB, OC & CD Level 3, category D, B & F Level 0. For wall thickness
2” to 4.5” comparable plates of ASTM E186 shall be used. ASTM E94 & ASTM E142 shall
be used for recommended practice & controlling quality of radiography as a guide. The entire
surface of all casting shall be dye-penetrant inspected after pickling.
Repair welds shall be 100% radiographed and evaluated in accordance with paragraph 344.5
of ASME B31.3 with a minimum casting quality factor of 0.95. Dye-penetration Test shall be
as per ASTM E-165 Procedure B-2, Interpretation as per Appendix 8 of ASME VIII Div 1.

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ANNEXURE - G
FOR LOW TEMPERATURE & CRYOGENIC
VALVES

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SPECIAL REQUIREMENTS FOR LOW TEMPERATURE & CRYOGENIC VALVES
1.0 Scope
All valves of Low Temperature Carbon Steel (LTCS) and all grades of austenitic SS (CRYO)
material are categorized as cryogenics valves. All these valves shall have extended bonnet as
per BS 6364 except check valves. Valves shall be suitable for installation in any position (on
vertical, horizontal or skewed pipe line).
Following qualification criteria shall be met by the valve vendors to quote valves for
cryogenic services.
2.0 Qualification criteria
Both cryogenic test (Clause 2.1) and reference list (clause 2.2) together, as indicated herein,
shall be considered for vendor qualification & vendor shall furnish the same, along with his
offer.
Vendors whose current supply does not cover valves of all sizes, materials and ratings
(cryogenic test and reference list) required by MR, should confirm / furnish the following for
consideration of their offer:
1. Evidence of having conducted successfully at least one cryogenics test as per BS 6364.
Test certificate and reference list shall be furnished with the offer.
2. Vendor shall confirm to conduct cryogenic test per clauses 2.1 & 2.3 for the remaining
valves not later than 12 weeks from the date of purchaser order.
Offers of vendors who do not comply with above requirements would be rejected.
Cryogenic test need not be conducted for every order. Test conducted previously, which need
not be against TEIL order, is sufficient.
2.1 Cryogenic test:
Vendors to furnish copies of cryogenic test certificate for tests conducted as per details given
below
1. Shall be as per BS 6364.
2. Test temperature, unless specifically called for otherwise in the individual MR, shall
be -45 0C for LTCS and -1960C for all grades of austenitic SS.
3. Tests carried out on a particular size of one of valve, pressure rating and material
shall qualify all sizes equal to and below the test valve size for the same type,
pressure rating and material. In case of austenitic SS any one grade would qualify for
all other grades of austenitic SS.

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4. Test shall have to be witnessed and certified by any one of the following third party
inspection agencies. M/S Lloyd, BV, DNV or TEIL. For vendors located in India
only TEIL witness and certification is acceptable.
2.2 Reference list
Vendor shall furnish reference list for valves supplied for cryogenic service indicating the
name of client, year of supply, size material, pressure rating, type of valve and quantity.
2.3 Post Order Testing Procedure :
1. Before conducting post order testing. Vendor shall submit the following for approval :
i. Test procedure (as per BS 6364)
ii. Cross-section drawing of the valve with material of construction.
iii. Schematic of test rig (as per BS 6364) with complete details.
2. Test has to be conducted on largest size order for each type of valve and for each
material and class rating. Vendor shall offer one, two or three valves for selection of
test valve by inspector depending upon whether quantity of largest valve in the order
is one, two or three and more than three respectively.
In the event of failure of the test valve to meet the specification requirements, the
vendor shall conduct test on two more valves. If the other two valves which pass test
successfully, are of lower size, then the qualification will be valid only to sizes up to
which test has been conducted successfully.
3. In case of non-conductance of cryogenic test(s) within 12 weeks or failure in the

test(s) conducted after receipt of order, the owner reserves the right to invoke any of
the provisions of the purchase order including cancellation of the purchase order at
the risk and cost of vendor.
3.0 Bonnet extension, wherever specified in the valve sheet to BS 6364 shall be for “ non cold
box application “unless otherwise specified in MR. Even if not called for in valve sheet,
valves indicated as “LT” or “CRYO” shall be supplied with bonnet extension.
4.0 Bonnet and gland extension joints shall be of butt welded construction.
5.0 Repair welding procedure for austenitic stainless steel valves in “CRYO” service shall have to
be qualified for impact test as per ASME B31.3. Minimum acceptable impact energy shall be
20 J or lateral expansion of 0.38 mm at temperature of -196 Dec. C.
6.0 Wherever impact test of SS studs/nuts is called for in the data sheet, the impact value shall be
27J at the intended service temperature specified in the data sheets

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ANNEXURE - H
FOR VACUUM SERVICE

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SPECIAL REQUIREMENTS FOR VACUUM SERVICE
1. Stiffener shall be provided as per ASME Sec. VIII Div.1.
2. Gasket shall have inner & outer Centering ring. Valve packing shall be with graphite ring.
Stem to have 32 microns RMS finishes. Body bonnet gasket to be spiral wound with inner
centering ring.
3. Valve shall be tested for vacuum by Hood’s technique as per ASME Sec.V Art.10.

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ANNEXURE-K
LICENSOR’S SPECIAL
REQUIREMENTS

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LICENSOR’S SPECIAL REQUIREMENTS
1. GENERAL
1.1 The showing of manufacturer’s names and catalogue or drawing numbers for valves and other
components in this project specification is intended to indicate quality, design, materials and
construction required for the particular service and not to be construed as an indication of
preference of manufacturer. Equivalent items may be substituted; however it is the
Contractor’s (or Purchaser’s in the absence of Contractor) responsibility to ensure
equivalency.
1.2 All flanges intended for use with spiral wound gaskets shall have a flange surface finish of
125 microinch Ra minimum to 250 microinch Ra maximum. Flanges intended for used with
other gaskets shall have a flange surface finish within the optimal range for the specified
gasket. Finishes shall be judged by visual comparison with surface finish roughness standards
conforming to ASME B46.1. It is the Contractor’s / Purchaser’s responsibility both to comply
with above finish requirement and to assure that such flange finishes be protected from
damage during shipping, storage and installation.
1.3 The minimum wall thickness for new pipes, excluding corrosion allowance and negative mill
tolerance, shall be Schedule 5S
1.4 Contractor shall be responsible for the compatibility of piping flanges with equipments &
instruments.
1.5 Contractor shall be responsible for the inclusion of the sustained, transient & thermal load
analyses cases. Detailed design of the piping supporting systems is the responsibility of the
contractor.
1.6 Lap joint flanges shall not be used in severe cyclic services.
1.7 Flanges and bolts shall be analyzed to insure that are not overstressed during gasket seating.
Overstressing is more likely to occur when class 300 and lower flanges are used with spiral
wound or metal gaskets.
1.8 Flanged thermowells and other flanged connections joining dissimilar materials required
special consideration. The flange class for both material shall be determined and the higher
class used for both flanges.
1.9 Threaded unions are permitted only for utility services such as air, water, nitrogen and
condensate. Unions shall be limited to class 300. Flanges shall be used in place of unions for
socket welded piping.
1.10 Provide valves with special trim as indicated on piping and instrument diagrams.
1.11 Locked open or car sealed open valves shall include metal tags permanently attached to the
valves. The tag shall read: “This valve must not be closed without written permission from
responsible authority.” The stem of Lock open or car seal open valves shall be installed in
horizontal position.

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1.12 For vacuum design, the minimum differential external pressure shall be 15psi (1.05 Kg/cm2)
1.13 Material for external vacuum stiffening rings shall be the same material as the pipe when the
design temperature is greater than 6500F (3400C). When the design temperature is 6500F
(3400C) or less, the material may be carbon steel.
1.14 All Killed carbon steel piping containing Amine at any concentration shall be Post Weld Heat
Treated (PWHT).
1.15 Post Weld Heat Treatment (PWHT) is required for monel piping in Hydrofluoric (HF) acid
service.
1.16 Requirements applicable to 1 Cr-1/2Mo and 1-1/4 Cr-1/2 Mo and 21/4 Cr – 1Mo
Materials
- All pressure containing components (regardless of size, thickness or product form) shall be
PWHT in accordance with requirement of ASME B31.3. No exemptions from PWHT are
permitted.
- The maximum room temperature tensile strength of all pressure containing component and
welds shall be 100,000 psi (7030 Kg/cm2)
- All fillet weld attached to pressure containing components shall be grounded to a smooth,
concave contour.
- All pressure containing welds, whether shop or field shall, be 100% radiographed. Branch
weld that cannot be radiographed shall be 100% ultrasonically examined.
- Accelerated cooling from the austenitizing temperature is acceptable, where permitted by

the applicable product from specification.
Additional requirements applicable to 1Cr-1/2Mo and 1-1/4Cr-1/2 Mo materials for

services with operating temperature over 8250F (4400C)
- Charpy V-notch impact testing is required for all pressure containing longitudinally fusion
welded pipe, components and welds. Impact test shall be conducted in accordance with the
requirements of ASME B31.3, except that there shall be no exemptions from impact testing
and test temperature shall be the lower of the design minimum metal temperature and 00F (-
180C). The test specimens shall be supplied in the same heat treated condition as the new
pipe.
- The product analysis content of Tin and Phosphorous for pressure retaining components
and welding consumables shall be less than 0.015% and 0.012% respectively. The
percentage limits are weight percent.

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2. For UOP’s Units refer following UOP – Standard / Project specifications:
Description UOP’s Standard / Project Specification No.

Naphtha hydrotreating Process Unit 947221 – 801, 806
CCR platforming Process Unit 947222 – 801, 806, 840
Cyclemax CCR Regenerarion 947223 – 801, 806
Shell Sulfolane Process Unit 947225 – 801, 806
Benzene-Toluene Fractionation Unit 947227 – 801, 806
Tatory Process Unit 947226 – 801, 806
Isomar Process Unit 947229 – 801, 806
Parex Process Unit 947228 – 801, 806, 840
Xylene Fractionation Unit 947224 – 801, 806
Piping 8-11-12
Fabrication of Piping 8-12-6
Plot plan design criteria for process
9-51-2
units

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MUMBAI INDIA TECHNICAL REQUIREMENTS FOR DOC. NO.

TOYO ENGINEERING INDIA LTD. PIPING MATERIALS 6249-A-00-481

ISSUE DATE 25-JAN-08 21-OCT-08 PAGE 13 OF 44

© TOYO ENGINEERING INDIA LTD

ISSUE DATE 25-JAN-08 21-OCT-08 PAGE 14 OF 44

2.0 DESIGN AND CONSTRUCTION

2.5 Yoke material shall be at least equal to body material.

© TOYO ENGINEERING INDIA LTD

ISSUE DATE 25-JAN-08 21-OCT-08 PAGE 15 OF 44

Stock Finish - 1000 µ in AARH max. (For Lap joint flanges)

Material Wall Thickness Weld Contour

Flange Material Min. hardness of Groove (BHN)

© TOYO ENGINEERING INDIA LTD

ISSUE DATE 25-JAN-08 21-OCT-08 PAGE 16 OF 44

VALVE SIZE RATING DESIGN STD. TESTING STD.

© TOYO ENGINEERING INDIA LTD

ISSUE DATE 25-JAN-08 21-OCT-08 PAGE 17 OF 44

a) Positive location / positioning of cover must be provided to ensure correct

2.19 Following valve bypass requirements shall be met:

Class For sizes

On main valve ≤ 4” 1/2 “ or more

© TOYO ENGINEERING INDIA LTD

ISSUE DATE 25-JAN-08 21-OCT-08 PAGE 18 OF 44

2.25 BALL /PLUG / BUTTERFLY VALVES :

© TOYO ENGINEERING INDIA LTD

ISSUE DATE 25-JAN-08 21-OCT-08 PAGE 19 OF 44

Class Floating Ball Trunnion Mounted

2.25.10 Use of soft-seated ball/plug/butterfly valves shall be suitably selected based on

2.25.11 Butterfly valve shall be suited for throttling application.

2.25.12 Use of fire safe valves shall be as per process requirement.

© TOYO ENGINEERING INDIA LTD

ISSUE DATE 25-JAN-08 21-OCT-08 PAGE 20 OF 44

2.32 Orientation of valves stem below horizontal position shall be avoided.

2.38 For licensor’s special requirements refer, Annexure-K

Valve Type Class Size requiring Gear-operator

© TOYO ENGINEERING INDIA LTD

ISSUE DATE 25-JAN-08 21-OCT-08 PAGE 21 OF 44

Totally enclosed bevel gear in grease case with

4.0 INSPECTION AND TESTING

1. Visual and dimensional inspection

© TOYO ENGINEERING INDIA LTD

ISSUE DATE 25-JAN-08 21-OCT-08 PAGE 22 OF 44

Cast steel valves:

1. Visual and dimensional inspection.

5.0 RADIOGRAPHY OF CAST VALVE

1) For hydrogen / hydrogen bearing hydrocarbons, oxygen, NACE services &

Class Size Qty.

2) For LT/CRYO services:

Class Size Qty.

3) For alloy steel and SS casting :

Class Size Qty.

© TOYO ENGINEERING INDIA LTD

ISSUE DATE 25-JAN-08 21-OCT-08 PAGE 23 OF 44

Class Size Qty. Remarks

© TOYO ENGINEERING INDIA LTD

ISSUE DATE 25-JAN-08 21-OCT-08 PAGE 24 OF 44

Flange Face : Wood or Plastic Cover

© TOYO ENGINEERING INDIA LTD

ISSUE DATE 25-JAN-08 21-OCT-08 PAGE 25 OF 44

© TOYO ENGINEERING INDIA LTD

ISSUE DATE 25-JAN-08 21-OCT-08 PAGE 26 OF 44

4. Basic design of bypass shall be to MSS-SP-45 & ASME B16.34.

6. This sketch is applicable for both BGO & NON-BGO valves.