annexure-1:technical specification of manual valves
TRANSCRIPT
1
ANNEXURE-1:TECHNICAL SPECIFICATION OF MANUAL VALVES
Type of valve
Tag No
Quantity
:
:
:
As given in Table 1
As given in Table 1
As given in Table 1
Actuation
Application
Fluid Medium
Working temperature range
Nominal Size (mm)
Pressure rating class
:
:
:
:
:
:
Hand-operated by wheel (Manual)
Isolation
As given in Table 1
300 – 310 K
As given in Table 1
As given in Table 1
Valve coefficient (Cv) : To be specified by the bidder in thequotation
Permissible leak rate acrossseat (through) in forwardand reverse directions
: Bubble-tight as per API 598 orRate A as per BS 6755 Part 1
End connection : As given in Table 1. The acronymsshall be read as follows:
BW: Butt welding ends as per ASME B16.25 and Pipe stubs as per ASME B /36.10 of 150 mm length each shall bebutt-welded to the body on eitherside, the ends of which shall beprepared for butt welding. The buttwelding ends shall be suitable to matewith the interfacing pipe of size &schedule number as given in Table 1.
Flanged: Raised Face (RF) flanges
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with serration as per ASME B 16.5.
Body : With full port (standard bore) and in-line end connections
Bonnet : Bolted or screwed to body withsuitable seals/ gaskets.
Stem : Rising stem with outside screw andYoke (OS&Y) pattern
Stem (dynamic) seal : By gland packing
Plug : Renewable (replaceable) from stem
Seat : Renewable from body with seat insert
Flow direction : Flow-to-open (globe valve)
Material of construction:
Body and bonnet : ASTM A 182 F 304/ 304L/ 316L/ 321(or) ASTM A 351 CF 3/3M /CF8 /8M
Stem, plug & seat : ASTM A 479 304/ 316/ 304L/ 316L/321
Gland packing : PTFE/ Glass-filled PTFE, PCTFE (Kel-F)
Plug and seat inserts : ASTM A 479 304L/ 316L /321
Pipe stub (end connection) : Seamless pipe, ASTM A 312 TP Gradesame as that of the body
Bolts : ASTM A 193 Gr B 8,
Nuts : ASTM A 194 Gr 8
The valves shall be either inherently anti-static or provided with anti-static features.
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Design code : BS 5352/ BS 1873/ API 6-D/ ASMEB16.34 / Relevant standard
Test code : BS 6755 Part 1/ API 598/ ASME B16.34/ Relevant standard
Tests:
a. Material test certificates: The material test certificates, detailingthe physical and chemical properties, of the principal pressure–bearing parts shall be provided.
b. Welding joint test (wherever applicable): All butt welding joints inthe valve shall be subjected to dye-penetrant test and radio-graphic test with X-ray or gamma ray to 2-2T sensitivity and allsocket weld joints shall be subject to Dye-Penetrant test.
c. Soundness test for castings (wherever applicable): All the castingsshall be subjected to soundness test with radio-graphic or ultra-sonic technique for flaw detection.
d. Hydraulic shell pressure test: The valve, upon final assembly, inpartially open position, shall be subjected to pressure test withWater (with suitable corrosion inhibitor) at 1.5 times the maximumrated working pressure of the particular pressure rating class ofthe valve.
e. Hydraulic seat pressure test: The valve, in closed position, shall besubjected to pressure test with Water (with suitable corrosioninhibitor) at 1.1 times the maximum rated working pressure of theparticular pressure rating class of the valve.
a. Pneumatic seat leak test: The leakage rate across seat shall betested with dry air or gaseous Nitrogen at 0.4 to 0.7 MPa (g) bywater displacement (bubble) method.
Cleanliness
All the interior flow surfaces of the valve shall be degreased andcleaned.
Marking
All the valves are assigned tag numbers for the sake of identification.The tag number for each valve, as indicated above, besides size,pressure rating class, material of construction, etc, shall be legiblyand indelibly engraved on the body of the valves.
Quality Assurance Plan: As given in Table 1A.
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Table 1: LIST OF MANUAL VALVES
SNo Tag number Type of
Valve Fluid medium Nominal size,metric
PressureRatingclass,metric
Schedulenumber ofinterfacing
pipeEnd connection Quantity,
Nos
1SVM 601A,
SVM 601B &SVM 601C
Globe GaseousHelium DN 15 PN 420 XXS
Butt weldingends as per
ASME B 16.253
2 TVM 702A Globe GaseousNitrogen DN 20 PN 420 XXS
Butt weldingends as per
ASME B 16.251
3 FVM 701A & FVM 701B Globe GaseousNitrogen DN 20 PN 520 XXS
Butt weldingends as per
ASME B 16.252
3
TVM 701,TVM 701A,TVM 701B,
TVM 701C, TVM 701D& TVM 701E
Globe GaseousNitrogen DN 25 PN 420 XXS
Butt weldingends as per
ASME B 16.256
4 SVM 901 A GateDe-
mineralizedwater
DN 32PN 250(MAWP-18 MPa)
_ANSI B 16.5
DN 32, 1500#SRF Flange
1
5 SVM 602A, SVM 602B,SVM 602C & SVM 602D Needle Gaseous
Helium
DN 15(MinimumInternal
Diameter:10 mm)
(MAWP-40 MPa) 160
Butt weldingends as per
ASME B 16.254
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Table 1A: QUALITY ASSURANCE PLAN FOR MANUAL VALVES
SNo Test Object tested Characteristic
sought forSample
sizeTest
procedureAcceptance
criterionForm ofrecord
Testperformed
by
Testwitnessed
by
Recordreviewed
by
1. Material testSpecimenfrom rawmaterials
Chemicalcompositionand physicalproperties
1 perlot
Relevantstandard
Relevant materialspecification
Materialcertificate
Vendor orThird partylaboratory
-Vendor,Inspector,Purchaser
2.Welding jointtest (whereverapplicable)
Socketwelding joints
Absence ofsurface defects 100 % Dye
penetrant testRelevantstandard
Testcertificate Vendor - Inspector,
Purchaser
Butt weldingjoints
Absence ofdefects 100 %
Dyepenetrant test&Radiographictest
ASME, Section IX Testcertificate Vendor - Inspector,
Purchaser
3.Soundness testfor castings(whereverapplicable)
Castings Absence ofdefects 100 %
Radiographicor ultrasonictest
Relevantstandard
Testcertificate Vendor - Inspector,
Purchaser
4. Dimensionalcheck Valve Dimensions 100 % Metrology
Relevantstandard/Purchaser-approved drawing
Testreport Vendor - Inspector/
Purchaser
5. Hydraulic shellpressure test
Valve in openposition
Structuralintegrity understress
100 %1.5 timesmaximumrated workingpressure
BS 6755 Part 1/API 598/Relevantstandard
Testcertificate Vendor Inspector Purchaser
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Table 1A: QUALITY ASSURANCE PLAN FOR MANUAL VALVES
SNo Test Object tested Characteristic
sought forSample
sizeTest
procedureAcceptance
criterionForm ofrecord
Testperformed
by
Testwitnessed
by
Recordreviewed
by
6. Hydraulic seatpressure test
Valve inclosedposition
Structuralintegrity of seatunder stress
100 %1.1 timesmaximumrated workingpressure
BS 6755 Part 1/API 598/Relevantstandard
Testcertificate Vendor Inspector Purchaser
7. Pneumatic seatleakage test
Valve inclosedposition
Leakage rateacross seat 100 %
Waterdisplacementmethod
BS 6755 Part 1/API 598/Relevantstandard
Testcertificate Vendor Inspector Purchaser
8. Cleanliness Valve Degreasing &Cleaning 100 % Relevant
standardRelevantstandard Certificate Vendor _ Inspector,
Purchaser
Notes: 1. Inspector: Third party inspection agency2. The Purchaser shall perform the Material Receipt Inspection (MRI).
1
ANNEXURE 2: SPECIFICATION OFBELLOW SEALED CRYOGENIC MANUAL VALVES
Type of valve : Extended Stem Bellow sealedcryogenic Globe manual valve
Tag number : As given in Table-2
Quantity : As given in Table-2
Actuation : By Hand wheel operation (or)Hand wheel with gear mechanism(for DN 100 valve)
Application : Shut-off/ isolation/ on-off
Fluid medium : As given in Table-2
Working temperature range : 77 to 310 K
Nominal size ( mm) : As given in Table-2
Maximum Allowable WorkingPressure (MAWP)
: As given in Table-2
Valve coefficient : To be specified by the bidder inthe quotation
Permissible Helium leakagerate across body
: 1E-7 Pa-m3/s (1E-6 mbar l/s.)
Permissible Helium leakagerate across seat in both thedirections
: 1E-6 Pa-m3/s (1E-5 mbar l/s.)
Guaranteed Cycles ofoperation
: 5,000
Length of stem extension : As per BS 6364 or equivalent
End connection:
BW: Butt welding ends as per ASME B 16.25, pipe stubs as perASME B 36.10 of 100 mm length each shall be butt-welded to
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the body on either side, the ends of which shall be prepared forbutt welding. The butt welding ends shall be suitable to matewith the interfacing pipe DN 100, schedule number 10S for valvesize DN 100 & pipe DN 25, schedule number 10S for valve sizeDN 25.
Style of construction:
Body : With full port (standard bore)and in-line end connections
Bonnet : Bolted or screwed to body withsuitable seals
Stem : Non-rotating, rising stem
Stem (dynamic) seal : By bellows with redundant glandpacking. Between the bellowsseal and the redundant glandpacking, a tell-tale indicatorpressure gauge shall be provided.
Plug : Renewable (replaceable) fromstem with insert
Seat : Integral with body and harderthan the plug insert
Flow direction : Flow-to-open (Flow-under-plug)
Material of construction:
Body, collar and bonnet : ASTM A 182 F 304/ 316/ 304L/316L/ 321 (or) ASTM A351 CF3/3M /CF 8/8M
Stem, plug, seat, seat insert : ASTM A 479 304/316/ 304L/316L/ 321
Bellows : Stainless steel 316L/ 316Ti/ 321/Hastealloy C 276/Inconel 600/ 625
Gland packing : PTFE/ Glass-filled PTFE/ PEEK
Plug insert/ trim : PCTFE (Kel-F)/ Polycarbonate/Vespel.
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Pipe stub : Seamless pipe - ASTM A 312 TP304L
Bolts : ASTM A 193 Gr B 8Nuts : ASTM A 194 Gr 8The valves shall be either inherently anti-static or provided withanti-static features.
Design code : EN ISO 15761 / BS 1873/ BS6364/ API 6-D/ ASME B16.34 orequivalent
Test code : EN ISO 12266-1 / BS 6364/ API598/ ASME B 16.34 or equivalent
Tests:
a. Material test certificates: The material test certificates, detailingthe physical and chemical properties, of the principal pressure–bearing parts shall be provided.
b. Bellows cyclic life test: Sample bellows drawn from each batch ofthe same size and type shall be subjected to (destructive) cycliclife (proto-type) test as per BS 5352/relevant standards. If themanufacturer of the bellows has already performed such test, copyof the certificate may be produced.
c. Welding joint test (wherever applicable): All butt welding joints inthe valve (including the joints between the body and the pipestubs) shall be subjected to dye-penetrant test and radiographictest with X-rays or gamma rays to 2-2T sensitivity as per SectionIX, ASME. All the socket welding joints shall be subject to dye-penetrant test.
d. Functional Test: Each valve has to be subjected to functional testfor free operation of valves to the full stroke length.
e. Soundness test for castings (wherever applicable): All the castingsshall be subjected to soundness test with radiographic orultrasonic technique for flaw detection.
f. Pre-assembly hydraulic shell pressure test: The valve shell, priorto assembly with the bellows, in partially open position, shall besubjected to pressure test with Water (with suitable corrosioninhibitor) at 1.5 times the maximum rated working pressure of theparticular pressure rating class of the valve.
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g. Final hydraulic shell pressure test: The valve, upon final assemblyincluding the bellows, in partially open position, shall be subjectedto pressure test with Water (with suitable corrosion inhibitor) at1.1 times the maximum rated working pressure of the particularpressure rating class.
h. Hydraulic seat pressure test (in both directions): The valve, inclosed position, shall be subjected to pressure test in both forward& reverse directions with Water (with suitable corrosion inhibitor)at 1.1 times the maximum rated working pressure of the particularpressure rating class of the valve.
i. MSLD shell leakage test: The global leakage rate across body shallbe measured with gaseous Helium Mass Spectrometer LeakageDetector (MSLD) to establish the permissible leakage rate valuesspecified above by hood technique as per Article 10, Section V,ASME. The leakage test shall be performed by shrouding the entireoutside surface of the valve with a plastic bag to hold gaseousHelium + gaseous Air mixture at a positive pressure and byevacuating and connecting the inlet/ outlet port to MSLD. Leakagetest by detector probe or tracer probe technique is not acceptable.
j. MSLD seat leakage test (in both directions): The global leakagerate across seat in both forward & reverse directions shall bemeasured with gaseous Helium MSLD to establish the permissibleleakage rate values specified above by hood technique as perArticle 10, Section V, ASME. The leakage test shall be performedby pressurizing the inlet with gaseous Helium + gaseous Airmixture and by evacuating and connecting the outlet to MSLD.Leakage test by detector probe or tracer probe technique is notacceptable.
Cleanliness
All the interior flow surfaces of the valve shall be degreased andcleaned to Oxygen service standards
Marking
All the valves are assigned tag numbers for the sake of identification.The tag number for each valve, as indicated above, besides size,pressure rating class, material of construction, etc, shall be legiblyand indelibly engraved on the body of the valves.
Quality assurance plan : As given in Table 2A.
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Table 2: LIST OF MANUAL BELLOW SEALED CRYOGENIC GLOBE VALVES
S No Tag number Fluid mediumNominal size,
metric(mm)
Maximumallowable
Working Pressure(MAWP) bar (a)
Schedulenumber ofinterfacing
pipe
Endconnection
Quantity,Nos
1 UVM 3001 Liquid Oxygen/Liquid Nitrogen DN 100 16 10 S
Butt weldingends as per
ASME B 16.251
2SVM 328,
SVM 328A &SVM 329
Liquid Nitrogen DN 25 12 10 SButt weldingends as per
ASME B 16.253
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Table 2A: QUALITY ASSURANCE PLAN FOR BELLOW SEALED CRYOGENIC MANUAL VALVES
SNo Test Object
testedCharacteristic sought for
Samplesize Test procedure Acceptance
criterionForm ofrecord
Testperformed
by
Testwitness
ed &certifie
d by
Recordreviewed
by
1. Material testSpecimenfrom rawmaterials
Chemicalcompositionand physicalproperties
1 per heat/lot
Relevantstandard
Relevant materialspecification
Materialcertificate
Vendor orThird partylaboratory
-Vendor,Inspector,Purchaser
2. Bellows cycliclife test Bellows Cyclic life
under fatigue
1 perbatch ofsame sizeand type
BS 5352 BS 5352 Testcertificate Sub-vendor -
Vendor,Inspector,Purchaser
3.Welding jointtest (whereverapplicable)
Socketweldingjoints
Absence ofsurfacedefects
100 % Dye penetranttest Relevant standard Test
certificate Vendor - Inspector,Purchaser
Buttweldingjoints
Absence ofdefects 100 %
Dye penetranttest &radiographic test
ASME, Section IX Testcertificate Vendor - Inspector,
Purchaser
4.
Soundnesstest forcastings(whereverapplicable)
Castings Absence ofdefects 100 % Radiographic or
ultrasonic test Relevant standard Testcertificate Vendor - Inspector,
Purchaser
5. Dimensionalcheck Valve Dimensions 100 % Metrology
Relevant standard/Purchaser-approved drawing
Testreport Vendor - Inspector,
Purchaser
7
Table 2A: QUALITY ASSURANCE PLAN FOR BELLOW SEALED CRYOGENIC MANUAL VALVES
SNo Test Object
testedCharacteristic sought for
Samplesize Test procedure Acceptance
criterionForm ofrecord
Testperformed
by
Testwitness
ed &certifie
d by
Recordreviewed
by
6.Pre-assemblyhydraulic shellpressure test
Valvebeforeassembly
Structuralintegrity understress
100 %1.5 timesmaximum ratedworking pressure
BS 6755 Part 1/API 598/ASME B 16.34
Testcertificate Vendor Inspect
or Purchaser
7.Final hydraulicshell pressuretest
Valve afterassembly
Structuralintegrity ofbody understress
100 %1.1 timesmaximum ratedworking pressure
BS 6755 Part 1/API 598/ASME B 16.34
Testcertificate Vendor Inspect
or Purchaser
8.Hydraulic seat(in bothdirections)pressure test
Valve inclosedposition
Structuralintegrity ofseat understress
100 %1.1 timesmaximum ratedworking pressure
BS 6755 Part 1/API 598/ASME B 16.34
Testcertificate Vendor Inspect
or Purchaser
9. MSLD shellleakage test
Valve inopenposition
Leakage rateacross body 100 % ASME, Section V,
Article 10Purchase orderspecification
Testcertificate Vendor Inspect
or Purchaser
10.MSLD seat (inbothdirections)leakage test
Valve inclosedposition
Leakage rateacross seat 100 % ASME, Section V,
Article 10Purchase orderspecification
Testcertificate Vendor Inspect
or Purchaser
11. Cleanliness ValveCleanliness forOxygenservice
100 % Relevantstandard Relevant standard Certificate Vendor - Inspector,
Purchaser
Notes: 1. Inspector: Third party inspection agency. 2.The Purchaser shall perform the Material Receipt inspection (MRI)
1
ANNEXURE 3: TECHNICAL SPECIFICATION OF CONTROL VALVES
The control valve shall comprise valve, actuator and smart positionerwith integrated I/P converter & position transmitter.
Actuator, positioner, Air filter & regulator, flow booster, Quick exhaustvalve should be interconnected properly with stainless steel tubings.
Quantity : As given in Table-3
Tag number : As given in Table-3
VALVE
Pattern : Globe
Application : Orifice with opening variable from 0to 100 %
Actuation : By pneumatic actuator
Configuration of ports/ ways : As given in Table-3
Fluid medium : As given in Table-3
Working temperature range : 300 -310 K
Orifice diameter/valve co-efficient (kv)
: To be calculated by the bidder andgiven in the quotation
Inlet nominal pipe size xschedule number
: As given in Table-3
Outlet nominal pipe size xschedule number
: As given in Table-3
Operating conditions:
Inlet temperature : As given in Table-3
Inlet pressure : As given in Table-3
Outlet pressure : As given in Table-3
Flow rate : As given in Table-3
Flow characteristic : As given in Table-3
Permissible leakage rateacross body
: As per ASME B 16.104
2
Permissible leakage rateacross seat
: Class VI as per ASME B 16.104/FCI 70.2 for resilient-seated valves
Class IV as per ASME B 16.104/FCI 70.2 for hard-seated valves
Guaranteed cycles ofoperation
: 5,000
End connection : As given in Table-3
Style of construction:
Body : With full port (standard bore) and in-line end connections
Bonnet : Bolted or screwed to body withsuitable seals/ gaskets
Stem : Non-rotating, rising stem
Stem (dynamic) seal : By gland packing
Plug : Renewable (replaceable) from stemwith insert
Seat : Renewable from body with ring(Alternatively, seat may be integralwith body provided that it is harderthan the plug insert.)
Flow direction : Flow-to-open (Flow-under-plug)
Material of construction:
Body and Bonnet : ASTM A 182 F 304/ 304L/ 316L/ 321(or) ASTM A 351 CF 3/3M /CF 8/8M
Stem, Plug, Seat & Seatinsert
: ASTM A 479 304/ 316/ 304L/ 316L/321
Gland packing : PTFE/ Glass-filled PTFE/ PEEK
Plug insert/ trim : PCTFE (Kel-F)/PEEK/ Vespel
Bolts : ASTM A 320 Gr B 8
3
Nuts : ASTM A 194 Gr 8
Design & test code : ASME B16.34/ ASME B 16.104/FCI 70.2
Tests:
a. Material certificates: The material certificates, detailing the physicaland chemical properties, of the principal pressure–bearing parts shallbe provided.
b. Welding joint test (wherever applicable): All butt welding joints in thevalve shall be subjected to dye-penetrant test and radiographic testwith X-rays or gamma rays to 2-2T sensitivity as per Section IX,ASME. All the socket welding joints shall be subject to dye-penetranttest.
c. Soundness test for castings (wherever applicable): All the castingsshall be subjected to soundness test with radiographic or ultrasonictechnique for flaw detection.
d. Hydraulic shell pressure test: The valve, upon final assembly, inpartially open position, shall be subjected to pressure test with Water(with suitable corrosion inhibitor) at 1.5 times the maximum ratedworking pressure of the particular pressure rating class of the valve.
e. Pneumatic seat leakage test: The leakage rate across seat shall betested with dry air or gaseous Nitrogen as per ASME B 16.104/FCI 70.2.
Cleanliness
All the interior flow surfaces of the valve shall be degreased and cleaned.
Marking
The valve body shall be engraved/marked with tag numbers, size,pressure rating class, material of construction, valve coefficient, etc.
ACTUATOR
Type : Linear actuator, piston/diaphragm type, single acting,spring return, fail-safe
Normal position : Closed.
Command gas : Gaseous Nitrogen at suitablepressure supplied by the
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positioner.
Response time (for bothopening and closing strokes)
: As given in Table-3
If required, flow (volume)booster and quick exhaust valveshall be incorporated to achievethe specified response time.
End connection for commandgas
: DN 15 (1/2”) NPT (F) to ASME B1.20.1.
Material : Carbon steel (enamel-painted)
Test The response time taken foropening and closing of the valveshall be evaluated.
SMART VALVE POSITIONER:
Functional specification:
Type : Microprocessor-based smartvalve positioner
Travel length : 3 to 100 mm for linear motion
Position sensing : Hall-effect sensor or contact type
Auto positioning : The positioner shall haveprovision to carry out autotuning, which is selectable byhand-held communicator or bylocal switches
Positioner input:
Input : 4 to 20 mA, 2-wire.Power supplied by the 4 to 20 mAcurrent only. No external powersupply.
Input range : Range shall be configurablethrough hand-held communicatoror by local switches
Voltage drop : 11 V DC maximum at 20 mA
5
Minimum current : 3.8 mA
Communication : HART protocol, digital signalsuperimposed on the 4 to 20 mAcurrent signal
Reverse polarity protection : Reverse polarity shall notdamage the positioner
Command gas supply : Gaseous Nitrogen at 0.7 ± 0.1MPa(g)
(If the positioner or actuator isdesigned for lesser pressure,suitable pressure regulator, alongwith filter, shall be provided.)
Positioner output:
Output to actuator : 0 to 100 % command gaspressure, double action
Command gas outputpressure
: 0.14 to 0.7 MPa(g)[20 to 100 psig]
Indication : 4½ digit LCD indicator
Feedback : 2-wire, 4 to 20 mA outputcorresponding to valve position
Output range : Shall be configurable throughhand-held communicator or bylocal switches
Flow characterization : Linear, equal percentage, quickopening, 16 freely selectablepoints
Gain : Selectable through hand-heldcommunicator or locallyadjustable
Travel time : Adjustable through hand-heldcommunicator or locallyadjustable
Performance specification:
Resolution : 0.1 % of full scale
Repeatability : 0.1 % of full scale
6
Hysterisis : 0.2 % of full scale
Command gas consumption : 0.25 Nm3/h at 0.14 MPa(g)supply pressure
0.7 Nm3/h at 0.56 MPa(g)supply pressure
Output capacity : 46.7 Nm3/h at 0.56 MPa(g)supply pressure
Operating temperature : 233 to 358 K (-40 to 85ºC)
Vibration effect : 0.3 % per 9.81 m/s2
EMI effect : To be designed to comply withIEC 801 and EN 50081 and EN50082
Physical specification:
Electrical connection : DN 15 (1/2”) NPT as per ASME B1.20.1.
Supply and outputpneumatic connection
: DN 15 (1/2”) NPT as per ASME B1.20.1.
Pressure gauge : Pressure gauges for supply andoutput command gas to beprovided
Mass : 3 kg approximate
Ingress protection class : IP 67
Make and model number : To be specified by the bidder inthe quotation
Suggested make : a. Smar, Brazilb. ABB, Germany
Quality assurance plan: As given in Table 3A.
Table-3: List of Globe Control ValvesOperatingconditions
Response time, s
Normal position
End connection
Flow characteristic
MAWP (Mpa)
Outlet nominal pipe size (metric)x Schedule number
Inlet nominal pipe size (metric)x Schedule number
Workingtemperature range, K
Fluid medium
Quantity, Nos
Tag number
Inlet temperature, K
Inlet pressure, MPa
Outlet pressure, MPa
Flow rate, kg/s
Closing
FullOpening
300
12.5
12 0.8
≤ 3 s
≤ 3 s
Close
ANSI B 16.5,DN 40, 2500#,Flange, RJF
50 : 1 Equal %
35
DN 40 X 160 S
DN 40 X 160 S
300-325 K
DM Water
1
FVC 913300
12.5
0.3 6
300
8.5 0.4 4.8
≤ 3 s
≤ 3 s
Close
ANSI B 16.5,DN 40,900#,Flange,SRF
50 : 1 Equal %
10
DN 40 X 40 S
DN 40 X 40 S
300-325 K
DM Water
1
TVC 901
300
6.6 0.4 4
300
5.4 0.4
12.6
300
4.7 0.4
15.7
300
3.5 0.4
15.9
8
Table 3A: QUALITY ASSURANCE PLAN FOR GLOBE CONTROL VALVES
Sl.No Test Object
testedCharacteristic
sought forSample
size Test procedure Acceptancecriterion
Form ofrecord
Testperformed
by
Testwitnessed& certified
by
Recordreviewed
by1. Material test Specimen
from rawmaterials
Chemicalcompositionand physicalproperties
1 perheat/ lot
Relevantstandard
Relevant materialspecification
Materialcertificate
Vendor orThird partylaboratory
- Vendor,Inspector,Purchaser
2. Welding jointtest (whereverapplicable)
Socketwelding joints
Absence ofsurface defects
100 % Dye penetrant(DP) test
Relevantstandard
Testcertificate
Vendor - Inspector,Purchaser
Butt weldingjoints
Absence ofdefects
100 % Radiographictest &DP test
ASME, SectionIX
Testcertificate
Vendor - Inspector,Purchaser
3. Soundness testfor castings(whereverapplicable)
Castings Absence ofdefects
100 % Radiographic orultrasonic test
Relevantstandard
Testcertificate
Vendor - Inspector,Purchaser
4. Dimensionalcheck
Valve Dimensions 100 % Metrology Relevantstandard
Testreport
Vendor - Inspector,Purchaser
5. Hydraulic shellpressure test
Valve in openposition
Structuralintegrity understress
100 % 1.5 timesmaximum ratedworkingpressure
BS 6755 Part 1/API 598
Testcertificate
Vendor Inspector Purchaser
6. Pneumatic seatleakage test
Valve inclosedposition
Leakage rateacross seat
100 % ASME B16.104/FCI 70.2
Purchase orderspecification
Testcertificate
Vendor Inspector Purchaser
7. Cleanliness Valve Degreasing &Cleaning
100 % _ _ Certificate Vendor - Inspector,Purchaser
8. Response timetest
Valve Response time 100 % Vendor’sstandard
Purchase orderspecification
Testcertificate
Vendor - Inspector,Purchaser
Notes: 1. Inspector: Third party inspection agency2. The Purchaser shall perform the Material Receipt Inspection (MRI).
1
ANNEXURE 4: TECHNICAL SPECIFICATION OFELECTROPNEUMATIC VALVE
The pneumatically-actuated valve shall comprise valve, actuatorand status switches.
A. VALVE
Tag number : SVP 901A
Quantity : 1 No.
Pattern : Gate
Application : Shut-off/ isolation/ on-off
Actuation : By pneumatic actuator
Fluid medium : DM water
Working temperature range : 300 – 310 K
Nominal size : DN 100
Pressure rating class as perASME
: 1500 lbs
Valve coefficient (Cv) : To be specified by the bidder inthe quotation
Permissible Helium leakagerate across body
: Bubble tight as per API 598
Permissible Helium leakagerate across seat
: Bubble tight as per API 598
Guaranteed Cycles ofoperation
: 5,000
2
End connection:
Flanged end connection, DN 100, 1500# Raised Face (RF) flangewith serration as per ASME B 16.5.
Style of construction:
Body : With full port (standard bore)and in-line end connections
Bonnet : Bolted or screwed to body withsuitable seals
Stem : Non-rotating, rising stem
Stem (dynamic) seal : By gland packing.
Gate Plug : Renewable (replaceable) fromstem with insert
Seat : Integral with body.
Material of construction:
Body and bonnet : ASTM A 351 F 304/ 304L/ 316L/321 (or) ASTM A 351 CF 3/3M/CF8 /8M
Stem, plug, seat, seat insert : ASTM A 479 304/ 316/ 304L/316L/ 321
Gland packing : PTFE/ Glass-filled PTFE/ PEEK
Plug insert/ trim : PTFE/ PCTFE/ Glass-filled PTFE/PEEK
Bolts : ASTM A 193 Gr B 8
Nuts : ASTM A 194 Gr 8
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Design code : BS 5352/ ASME B 16.34/RelevantASME sandard
Test code : BS 6755 Part 1/ API 598/ ASMEB16.34/ Relevant ASME std
Tests:
a. Material test certificates: The material test certificates, detailingthe physical and chemical properties, of the principal pressure–bearing parts shall be provided.
b. Welding joint test (wherever applicable): All butt welding joints inthe valve (including the joints between the body and the pipestubs) shall be subjected to radiographic test with X-rays orgamma rays to 2-2T sensitivity as per Section IX, ASME. All thesocket welding joints shall be subject to dye-penetrant test.
c. Hydraulic shell pressure test: The valve, upon final assembly, inpartially open position, shall be subjected to pressure test withWater (with suitable corrosion inhibitor) at 1.5 times the maximumrated working pressure of the particular pressure rating class.
d. Hydraulic seat pressure test: The valve, in closed position, shall besubjected to pressure test with Water (with suitable corrosioninhibitor) at 1.1 times the maximum rated working pressure of theparticular pressure rating class of the valve.
Cleanliness
All the interior flow surfaces of the valve shall be degreased andcleaned.
Marking
The valve body shall be engraved/marked with tag number, size,pressure rating class, material of construction, etc.
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B. ACTUATOR
Type : Linear actuator, piston/diaphragm type, single acting,spring return, fail-safe
Normal position : Closed
Command gas : Gaseous Nitrogen at 0.6 to 0.8MPa(g)
Response time (for bothopening and closing strokes)
: 5 s
If required, flow (volume)booster and quick exhaust valveshall be incorporated to achievethe specified response time.
End connection for commandgas
: DN 15 (1/2”) NPT (F) to ASME B1.10.1
Material : Carbon steel (enamel-painted)
Test The response time taken foropening and closing of the valveshall be evaluated.
C. STATUS SWITCHES
TypeCylindrical Inductive Type ProximitySensor (switch) in accordance withNAMUR
Sensing Distance
The sensing distance shall besuitably selected by the valvemanufacturer according to thevalve stroke length.
Electrical Configuration DC, 2 wire
Nominal Voltage 8 V
Operating Voltage 5 – 25
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Switching Frequency ≥ 500 HZ
Reverse Polarity Shall be Protected against reversepolarity
Short-Circuit protection Shall be Protected for short circuit
CurrentConsumption
NotSensing ≥ 3 mA
Sensing ≤ 1 mA
Indication of switchingstate LED
Connection Type 2 metre long PVC Cable
Ambient Temperature - 250C to 800C
Housing Material Stainless Steel
Protection Degree IP 67
Safety Aspects Shall be intrinsically safe forHydrogen (IIC) ambience
Certification ATEX 1G EEx ia IIC T6
Note:
1. The valve shall be provided with pair of switches for meeting
the above specification.
2. The switches shall be mounted in the valve with proper
mounting arrangement so that it does not require any
adjustment / alignment for a minimum period of 5000 cycles
(opening/closing) of operation of valve.
3. The specification matrix (including Make & Model) of the
status switch shall be provided to the Department prior to
procurement of status switches for approval.
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Suggested Make:
a. PEPPERL & FUCHS - Germanyb. OMRON – USAc. Rockwell Automation – USAd. LongVale Ltd – UKe. Euroswitch - UKf. Cario Gavazzig. IFM electronic
D. Quality Assurance Plan : As given in Table 4A.
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Table 4A: QUALITY ASSURANCE PLAN FOR ELECTRO PNEUMATIC VALVESNo
Test Object tested Characteristicsought for
Samplesize
Testprocedure
Acceptancecriterion
Form ofrecord
Testperformedby
Testwitnessed &certified by
Recordreviewedby
1. Material test Specimenfrom rawmaterials
Chemicalcompositionand physicalproperties
100% Relevantstandard
Relevantmaterialspecification
Materialcertificate
Vendor orThird partylaboratory
- Vendor,Inspector,Purchaser
2. Welding jointtest (whereverapplicable)
Socketwelding joints
Absence ofsurface defects
100 % Dye penetrant(DP) test
Relevantstandard
Testcertificate
Vendor - Inspector,Purchaser
Butt weldingjoints
Absence ofdefects
100 % Radiographictest & DP test
ASME, SectionIX
Testcertificate
Vendor - Inspector,Purchaser
3. Dimensionalcheck
Valve Dimensions 100 % Metrology Relevantstandard
Testreport
Vendor - Inspector,Purchaser
4. Hydraulic shellpressure test
Valve in openposition
Structuralintegrity of bodyunder stress
100 % 1.5 timesmaximumrated workingpressure
RelevantASME / APIstandard
Testcertificate
Vendor Inspector Purchaser
5. Hydraulic seatpressure test
Valve inclosedposition
Structuralintegrity of seatunder stress
100 % 1.1 timesmaximumrated workingpressure
RelevantASME / APIstandard
Testcertificate
Vendor Inspector Purchaser
6. Cleanliness Valve Degreasing &Cleaning
100 % Relevantstandard
Relevantstandard
Certificate Vendor - Inspector,Purchaser
7. Response timetest
Valve Response time 100 % Vendor’sstandard
Purchase orderspecification
Testcertificate
Vendor - Inspector,Purchaser
Notes: 1. Inspector: Third party inspection agency2. The Purchaser shall perform the Material Receipt Inspection (MRI).
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ANNEXURE 5: SPECIAL CONDITIONS FOR MANUAL VALVES,BELLOW SEALED CRYOGENIC MANUAL VALVES,
CONTROL VALVES AND ELECTRO PNEUMATIC VALVE
1. Guarantee/warranty: The valves shall be guaranteed/warranted for satisfactory performance over a period of 18months from the date of dispatch from the vendor’s factory or12 months from the date of commissioning at the purchaser’ssite, whichever is earlier.
2. Inspection: The Inspection of the valves shall be carried out bythe Third Party Inspection (TPI) agency. The scope ofinspection shall be as per the Quality Assurance Plan (QAP)given in Tables 1A, 2A, 3A & 4A and Technical specifications asgiven in Annexure 1, 2, 3 & 4.
TPI agency, shall be chosen from the following list only:
a. Lloyds Register Industrial Services Pvt Ltd (LRIS)b. Bureau Veritas Industrial Services Pvt Ltd (BVIS)c. Det Norske Veritas (DNV)d. Technischer Uberwachungs Verein (TUV)e. Bax Counsel Inspection Bureau Pvt Ltd
It shall be the responsibility of the vendor to arrange for andcoordinate with the TPI agency.
3. Spares: The spare parts and special tools required for operationand maintenance of the valves for 2 years shall be supplied.The detailed list of such spares shall be mentioned in thequotation.
4. Documentation: The following documents (2 copies, in English)shall be provided by the vendor at the different stages specifiedthereupon:
4.1. Along with Techno commercial bid (Part-I):
The following documents/details shall be provided:
4.1.1. Complete technical description, including valve co efficientalong with drawings & catalogues of all the valves quoted.Make& model No. of positioner, sizing calculations for the controlvalves quoted.
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4.1.2. Deviations, if any, from the tender enquiry specification shallbe explicitly spelt out. Otherwise it will be presumed that theoffer is as per tender specification.
4.1.3. The company profile of the vendor highlighting the following:
a. Status as to whether the vendor is a valve manufacturer,trader, dealer, stockiest, agent, etc.
b. Infrastructural facilities such as factory area, machineries,equipments, material handling devices, instruments, tools,tackles, etc owned by the vendor.
c. Previous experience: Bidder shall submit evidence ofprevious experience in the form of Purchase order and ThirdParty Inspection certificate of Manual valves, Control valves,cryogenic valves & Electro pneumatic valves supplied in thepast.
d. Clientele specifying the clients to whom the vendor hassupplied similar cryogenic valves indicating their address,telephone, fax, email, contact person, etc.
4.1.4. Non acceptability of part order should be indicated in thequotation otherwise it will be presumed that part order isacceptable.
4.1.5. If any of the details required as per tender are not provided theoffer will be summarily rejected.
4.1.6 The bidder strictly should not indicate the price break-updetails in Techno-Commercial bid (Part-I), otherwise thebid will be summarily rejected.
4.2 Along with Price bid (Part-II):
The bidder shall indicate the price break-up details such asbasic valve price, testing charges, inspection charges, sparesprice, freight, taxes & duties, packing & forwarding charges,etc. only in the Price bid (Part-II).
4.3 Within 2 WEEKS from placement of purchase order, thefollowing documents shall be provided. These documents aresubject to review by the purchaser. Only upon receipt of the
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Purchaser’s approval of these documents, the vendor shallproceed with manufacture of the valves. However, thepurchaser’s approval shall not absolve the vendor of theirresponsibility to comply with the specification of purchaseorder.
4.3.1 General Arrangement (GA) drawing, indicating the overalldimensions of the product along with the accessories.
4.3.2 Detailed cross sectional/ fabrication drawing of the valve,indicating the dimensions and Material of Construction (MOC) ofeach trim/ part.
4.4 Upon satisfactory inspection of the valves, the followingdocuments shall be provided. The purchaser shall review thesedocuments for compliance with the specification of thepurchase order and issue “purchaser’s delivery clearance”. Onlyupon receipt of the same, the vendor shall proceed withdelivery of the valves.
4.4.1 Certificates of tests specified in Annexure 1 (for manualvalves), Annexure-2 (for bellow sealed cryogenic manualvalves), Annexure-3 (for Control valve) and Annexure-4 (forElectro pneumatic valve) shall be authorized by the inspector.
4.4.2 Inspection report by the inspector.
4.5 Along with the consignment, the following documents shallbe provided:
4.5.1 Instruction manual for installation, operation, maintenance andtrouble-shooting.
4.5.2 Guarantee/ Warranty certificate.
5 The delivery period for supply of valves shall be 5 monthsfrom the date of Purchase Order.