59042358 Spec for Shutdown Valves
January 28, 2017 | Author: Yogesh Kumar Bhatnagar | Category: N/A
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Download 59042358 Spec for Shutdown Valves...
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VECO Doc. No. 20298-01-EJ12-022 Project Title
MEHAR GAS DEVELOPMENT PROJECT Area
Location
12
MGDP
Discipline
I
Document No.
1042
Rev.
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TABLE OF CONTENTS 1.0
INTRODUCTION.............................................................................................................4
1.1
General ...........................................................................................................................4
1.2
Scope ..............................................................................................................................4
1.3
Definitions .......................................................................................................................4
1.4
Environmental Conditions................................................................................................5
1.5
Vendor's Responsibility ...................................................................................................6
1.6
Codes, Standards and Specifications ..............................................................................6
2.0
GENERAL REQUIREMENTS .........................................................................................8
3.0
TYPES OF VALVES AND THEIR APPLICATION ..........................................................8
3.1
General ...........................................................................................................................8
3.2
Shutdown Valves.............................................................................................................9
3.3
Solenoid Valves.............................................................................................................10
4.0
BODY CONSTRUCTION AND MATERIALS ................................................................10
4.1
General .........................................................................................................................10
4.2
Body Size ......................................................................................................................10
4.3
End Connection.............................................................................................................11
4.4
Face-to-Face Dimensions..............................................................................................11
4.5
Materials........................................................................................................................11
4.6
Stuffing Box and Packing...............................................................................................11
4.7
Gaskets .........................................................................................................................12
5.0
VALVE TRIM AND SEAT RING....................................................................................12
5.1
Seat Leakage and Flow Direction ..................................................................................12
5.2
Construction ..................................................................................................................12
5.3
Materials........................................................................................................................12
6.0
VALVE ACTUATOR .....................................................................................................13
6.1
General .........................................................................................................................13
6.2
Shutdown Valve Actuator ..............................................................................................16
6.3
Actuator Colour Coding .................................................................................................17
6.4
Stroking Time ................................................................................................................17
7.0
ACCESSORIES ............................................................................................................18
7.1
Hand Wheels.................................................................................................................18
VECO Doc. No. 20298-01-EJ12-022 Project Title
MEHAR GAS DEVELOPMENT PROJECT Area
Location
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Discipline
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7.2
Lock-up Valves..............................................................................................................18
7.3
Limit Switches ...............................................................................................................18
7.4
Air Lubricators ...............................................................................................................19
7.5
Solenoid Valves.............................................................................................................19
7.6
Filter Regulators ............................................................................................................20
7.7
Filters ............................................................................................................................20
7.8
Volume Boosters ...........................................................................................................21
8.0
VALVE IDENTIFICATION .............................................................................................21
9.0
INSPECTION AND TESTING .......................................................................................21
9.1
Extent ............................................................................................................................21
9.2
Dimensional and Flange Face Finish Check..................................................................22
9.3
Hydrostatic Test ............................................................................................................22
9.4
Functional Test..............................................................................................................23
9.5
Seat Leakage Test ........................................................................................................23
10.0
MATERIALS AND INSPECTION CERTIFICATION ......................................................23
11.0
WITNESSING BY ENGINEER/ COMPANY ..................................................................23
12.0
PROTECTION AND PACKAGING................................................................................23
13.0
DOCUMENTATION.......................................................................................................24
VECO Doc. No. 20298-01-EJ12-022 Project Title
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Location
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1.0
INTRODUCTION
1.1
General
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PETRONAS CARIGALI (Pakistan) Ltd. (PCPL) is undertaking the development of Mehar Gas Field in Mehar Block (Block 2767-1) located in Sindh and Balochistan Provinces of Pakistan. PCPL intends to develop the Mehar Field by installing a Gathering System, Gas Processing Facility (GPF) and Product Storage & Loading Facilities. The field facilities will be developed in two phases, Phase-I and Phase-2. Phase-1 development will cater to 55 MMSCFD of gas productions and Phase-2 will cater to 80 MMSCFD of gas productions. The expected condensate production rate is 6600 BPD for Phase-I and 7000 BPD for Phase-2. From GPF, treated sales gas will be exported through a new pipeline to existing SSGCL/SNGPL gas pipeline. Stabilized condensate and produced LPG will be exported by road tankers. Mehar Block is located in the Kirthar Fold belt area, in the Middle Indus Basin. Mehar field is located about 190 km west of Sukkur and 400 km north of Karachi in Sindh province. The environment is arid and the terrain is mountainous. Mazarani gas field, operated by PPL is situated about 25 km to the north, while Zamzama gas field operated by BHP is situated about 70 km to the north of Mehar Field. Mehar field consists of Pab and Ranikot formations. The wells will be connected to the new GPF through a Gathering System. There will be a total of 8 wells (4 in Pab & 4 in Ranikot) in Phase-1 and 3 additional wells (2 in Pab & 1 in Ranikot), totaling 11, in Phase-2 of the Mehar field development. 1.2
Scope This Specification, together with all reference documentation, defines the minimum technical requirements for the sizing, selection, design, manufacture, test, supply, install, documentation and preparation for shipment of Shutdown Valves for Mehar Gas Development Project. The CONTRACTOR shall use this specification together with other detailed instrument specifications, datasheets supplied to establish the detail design and final selection of Valves in their proposal. This specification shall not be considered all-inclusive. The VENDOR shall submit full technical details of their standard equipment, which meet the requirements herein. Aspects of the requirements, which cannot be met, shall be identified and variances explained.
1.3
Definitions COMPANY
Petronas Carigali Pakistan Limited (PCPL) or any Third Party assigned by the COMPANY
VECO Doc. No. 20298-01-EJ12-022 Project Title
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ENGINEER
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Party which carries all or part of the design, engineering of the PROJECT. VECO Engineering, Abu Dhabi is the ENGINEER. Party which carries out all or part of the design, engineering, procurement, construction, commissioning or management, of the PROJECT. EPCC CONTRACTOR includes his approved, MANUFACTURERS, SUPPLIERS, VENDORS and SUBCONTRACTORS.
EPCC CONTRACTOR
1.4
Rev.
MANUFACTURER/SUPPLIER/VENDOR
Party/ies, which manufacture and/or supply materials, equipment and services to perform the duties as specified by the CONTRACTOR in the scope of supply.
PROJECT
MEHAR PROJECT
WORKS
All temporary and permanent work described in this specification and in the Contract
Shall
Indicates a mandatory requirement
Should
Indicates a strong recommendation to comply with the requirements of this document
BDV
Blowdown Valve
FAT
Factory Acceptance Test
IP
Ingress Protection
MAWP
Maximum Allowable Working Pressure
SDV
Shutdown Valve
SPDT
Single Pole Double Throw
GAS
DEVELOPMENT
Environmental Conditions Wellhead facilities, Gathering stations and Gas Processing Facility (GPF) area has been tentatively selected at a location about 190 km west of Sukkur and 300 km north of Karachi in Sindh Province. The environment is arid the terrain is mountain. The Environmental conditions are: Maximum Ambient Temperature
:
55ºC
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Minimum Ambient Temperature
:
0.5ºC
Wet bulb temperature (design)
:
30ºC
Relative humidity (max / nor /min )
:
90 / 65 / 20 %
Direction of prevailing wind
:
From south to north
Wind Velocity (max / normal)
:
Hold / 2.9 knots
Elevation above mean sea level (GPF)
:
54m (Site-IV) / 56m (Site-l)
Average barometric pressure
:
1001.2 mbar (29.56 inches of Mercury)
Ice / Snow
:
None
Seismic zone
:
Zone 2B, upper moderate with ground acceleration of 0.2(Hold)
Annual rainfall min.
:
63.3 mm (year 2006)
Annual rainfall max.
:
139.9 mm (year 2005)
Vendor's Responsibility The VENDOR shall have responsibility for complete engineering approach to the valves sizing, design, selection, fabrication, engineering, testing, calibration, supply, documentation, and shipment. The COMPANY’S approval of the manufacture and model number of valves and approval of the VENDOR'S drawings/documents does not in any way affect the VENDOR'S full responsibility to supply strictly in accordance with project specifications, codes and standards. This Specification shall not relieve the VENDOR of any responsibility to provide equipment and services that are suitable for the intended duty.
1.6
Codes, Standards and Specifications
1.6.1
General Codes, specifications and standards referred to within this specification, form a part of the requirements of this specification in a manner and to the extent specified within those codes and standards. Unless otherwise specified, the latest edition or revision to these codes specifications, and standards in force at the time of request for quotation and/or Purchase Order shall apply. The CONTRACTOR shall apply all Standards and Codes in accordance with COMPANY requirements. Should conflict arise between the statements of different rules, codes or standards, the CONTRACTOR shall comply with the requirements in the following order of priority:
VECO Doc. No. 20298-01-EJ12-022 Project Title
MEHAR GAS DEVELOPMENT PROJECT Area
Location
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Discipline
MGDP
Document No.
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1042
•
Government Legislation
•
Data Sheets and Material Requisition
•
Project Specification
•
Basic Design Drawing
•
International Codes & Standards
•
Company Specifications (PTS)
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Should different, non-conflicting requirements be made by different rules, codes or standards, the most stringent one shall apply, and clarification should be sought from COMPANY. 1.6.2
Regulations The CONTRACTOR shall be responsible to investigate the requirements of all applicable local regulations, Codes and Standards together with the requirements of the local Certifying Authorities.
1.6.3
Reference Standards IEC 60529
:
Classification of Degrees of Protection Provided by Enclosures
ASME B16.5
:
Pipe Flanges and Flanged Fittings
ASME B.16.34
:
Valves-Flanged, Threaded and Welded End
ASME B.46.1
:
Surface Texture/Roughness and Waviness
API 598
:
Testing / Inspection Requirement For Gate, Globe Valves Etc
API 6D
:
Specification for Pipeline Valves (Gate, Plug, Ball and Check Valves)
ASTM A 193 & A 194
:
Carbon and Alloy Steel Nuts and Bolts for High Pressure Service
:
Material Requirements for Sulphide Stress Cracking Resistant Metallic Material for Oilfield Equipment (2003 Edition)
BS 5351
:
Specification for Steel Ball Valves for The Petroleum, Petrochemical And Allied Industries
BS 6755 PT – 1
:
Specification for Type Testing Requirements
BS EN ISO 10497
:
Testing of Valves Fire Type Testing Requirements
NACE-MR0175 ISO15156
/
VECO Doc. No. 20298-01-EJ12-022 Project Title
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ISO 9001:2000
:
Quality Management Systems – Requirements
PTS 20.080
:
Actuated Ball Valves
PTS 31.36.10.30
:
Hydraulic systems for remote operation of shut-off valves
PTS 31.38.01.12
:
Piping Classes – Refining and Chemicals
PTS 32.36.01.17
:
Control Valves – Selection, Sizing and Specification
PTS 32.36.21.93
:
Solenoid-Operated Valves (Requistion Sheet) PTS 32.36.21.93
PTS 32.45.10.10
:
Instrumentation of Depressuring Systems
PTS 32.80.10.10
:
Classification and Implementation of Instrumented Protective Functions
PTS 70.10.90.11 2.0
:
Spare Parts
GENERAL REQUIREMENTS In general, PTS 32.36.01.17 and PTS 20.080, on control valve sizing, selection and specification and Actuated Ball Valves shall be followed for any other elements not outlined below.
3.0
TYPES OF VALVES AND THEIR APPLICATION
3.1
General Unless otherwise specified in the instrument data sheets or dictated by its application, the selection of a type of valve should be in the following order of preference: •
Ball valve;
•
Butterfly valve;
Design shall be in accordance with API Standard 6D for pipeline shutdown valves and to API 6D or BS 5351 for non pipeline shutdown valves as specified in the requisition. The materials and rating of valves shall be in accordance with the piping class. Valves specified to BS 5351 are acceptable in the following sizes ANSI Class Size: •
150, DN 250 and below;
•
300, DN 40 and below.
VECO Doc. No. 20298-01-EJ12-022 Project Title
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Location
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All identification and/or instruction plates on the valve, actuator and accessories shall be of stainless steel and be fixed with screws or rivets. Blow down valves noise shall be less than 110 dB at a 3 m distance. Cadmium plating or galvanising shall not be used for any component of the valves assembly or its accessories. 3.2
Shutdown Valves Unless otherwise required, emergency shut-off valves shall be designed and installed as “flow-tending-to-close”. ESD and On / Off valves materials of construction, valve design, and standards shall be selected in accordance with Piping Material Specification 12-MGDP-P-1000. The exception is the valve stem material, which shall be selected to withstand the maximum torque / thrust of the actuator (Refer to section 6.0), and consideration given to the frequency of valve use.
3.2.1
Ball Valves Ball valves shall be considered for on-off service. Ball valves shall comply with the piping class. The type of actuator shall be as per datasheet or as specified by the COMPANY. Ball valves for use in erosive (e.g. slurry) service etc. should be equipped with a scraper type of seat construction. Ball valves shall not be selected for throttling service without the approval of the COMPANY. Unless equipped with a special trim, i.e. anti-cavitation or low-noise design, care should be taken with the selection of ball valves for high differential pressures.
3.2.2
Butterfly Valves Butterfly valves shall be considered for the following circumstances subject to COMPANY approval: •
If the required size (usually due to a high flow rate with a low pressure drop) would make it economically attractive;
•
If it is impossible to use eccentric plug/ segmented ball;
"High performance butterfly valves" can be used for high temperatures and high differential pressures, with Class V or Class VI shut-off performance application. Spring-opening butterfly valves should not be of the wafer or lug type but should have a valve body (in order to allow removal of the valve from the piping system). If a wafer or lug type butterfly valve is used (shall only be considered for non-hydrocarbon service), a
VECO Doc. No. 20298-01-EJ12-022 Project Title
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hand wheel or spool pieces (upstream and downstream) may be specified to permit removal of the valve. The provision of a hand wheel shall be subject to the approval of the COMPANY. Where butterfly valves are installed in vertical piping, it shall be arranged so that the diaphragm actuator remains clear of the piping. 3.3
Solenoid Valves Apart from their use in instrument air signal lines, solenoid valves may only be considered for on-off control in hydraulic utility services, such as hydraulic control systems for remotely operated valves and wellhead control units as required by Company. Solenoid-operated valves shall, unless otherwise specified, be normally closed valves suitable for continuous operation at the supply voltage.
4.0
BODY CONSTRUCTION AND MATERIALS
4.1
General Body construction may be split body with flanged ends or all welded body as specified on the requisition. Split body design shall be utilised in sizes of DN 600 ANSI class 900 and below to facilitate shop maintenance. Top entry valves shall not be specified as insitu maintenance is not a requirement. Top entry valves may, however, be accepted should they be offered and are commercially attractive. All valves shall be flanged end type. Shutdown valves, other than wafer/wafer lug type butterfly valves, shall be provided with flanges. Wafer type valves and lug flanges shall only be considered for non hydrocarbon service. Valve bonnets shall be of bolted construction with fully retained gaskets. For valves DN 450 and above, VENDOR shall clearly state in his proposal the maximum allowable bending moment which may be applied to the valve body. Both metal and soft seated valves shall be to a fire-tested design. Copies of applicable certification shall be provided with the bid for the valves. The materials of construction for all components of the valve shall be clearly listed in the proposal.
4.2
Body Size Emergency shut-off valves shall be sized for the process conditions, and the pressure drop shall be kept to a minimum. For ball valves, full bore valve is the first choice, reduced bore valve may be considered only if approved by the COMPANY.
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End Connection The ASME rating class of flanges shall be in accordance with the piping class unless otherwise specified. Flanges shall be in accordance with ASME B16.5 or ASME B16.47, as applicable. The flange gasket contact surface finish shall be in accordance with ASME B16.5. Welding of flanges is not acceptable.
4.4
Face-to-Face Dimensions The face-to-face dimensions of lug and wafer type butterfly valves shall be in accordance with BS 5155. The face-to-face dimensions of flanged rotary valves (segmented ball) shall be in accordance with either API 6D or IEC 60534-3-1.
4.5
Materials The material selection of the body (including bonnet and/or bottom flange), external bolts, studs and nuts, etc. shall be in accordance with the valve data sheet and piping material specification. All valve materials for sour service shall conform to the latest edition of NACE MR-0175 / ISO15156 standards.
4.6
Stuffing Box and Packing
4.6.1
General The packing materials shall be: •
PTFE-based for temperatures at the packing below 200°C;
•
Graphite-based, for temperatures at the packing between 200°C and 600°C.
Packing shall not contain asbestos. Air cylinder and piston material shall be such that no external lubrication supply is necessary. Depending upon the design of the valve, an extended bonnet may be required to keep the temperature at the stuffing box at an acceptable value for the applied packing. An extended bonnet may also be required if the operating differential pressure across the valve could otherwise cause freezing of the stuffing box/packing and/or ice formation on the yoke. The stuffing box shall be provided with an adjustable bolted gland flange and gland follower. The valve gland shall be properly adjusted by the valve VENDOR. If, for
VECO Doc. No. 20298-01-EJ12-022 Project Title
MEHAR GAS DEVELOPMENT PROJECT Area
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technical reasons, the valves are delivered with a loose gland, this shall be clearly indicated on the appropriate valve with a warning sign. 4.7
Gaskets Unless otherwise dictated by the process conditions and piping specification, the gasket material shall be AISI 316 type stainless steel, graphite filled. The filler material shall be expanded graphite with the following specification: •
Maximum 1% ash content;
•
Maximum 50 mg/kg chloride content;
•
Density range 0.7 to 1.8 g/cm3.
Other types of gasket shall be subject to the approval of the COMPANY. 5.0
VALVE TRIM AND SEAT RING
5.1
Seat Leakage and Flow Direction Unless otherwise required, on-off and emergency shut-off valves should be specified and installed as "fail-to-close". The direction of the shut-off requirement (for one or both directions) shall be as indicated on the relevant P&ID’S. Balanced-type single-seated control valves of the pilot-operated type shall not be used as TSO valves. For seat leakage testing, reference is made to (9.5).
5.2
Construction The plug and the seat ring(s) shall be of the easy/quick replaceable type. Special attention shall be paid to fixing of the seat ring in order to prevent loosening due to vibration. Adhesive compounds shall not be used for the locking of seat rings. If required, the valve stem part that is exposed to the surrounding atmosphere shall be completely covered by a protection bellows. This protection bellows shall be of a material, which is resistant to corrosion by the product and the environment. Lifting lugs shall be provided for valves 3” in size and larger.
5.3
Materials The shutdown valve trim shall be corrosion resistant and of the grade specified in the data sheets. For fluids that become corrosive when in contact with the atmosphere, suitable valve stem and trim materials shall be considered or precautions shall be taken to prevent contact with air.
VECO Doc. No. 20298-01-EJ12-022 Project Title
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Where soft (resilient) inserts are required for meeting the specified leakage rate, the selection shall be based on their suitability for the specified process conditions. The resilient insert shall be properly clamped between metal parts and/or locked in position to prevent blowout in the closed position. Hardened, (e.g. Stellite or Colmonoy-coated) or solid Stellite closure members and seat rings shall be selected for the following applications: •
Erosive services, cavitating services and choked flow;
•
Wet gas with a pressure drop greater than 5 bar;
•
Other services in which the pressure drop is greater than 20 bar at temperatures above 300°C.
For economic reasons, and if suitable for the specified process conditions, hardened AISI 440C type stainless steel (hardness approximately 550 BHN) may be considered as trim material if approved by the COMPANY. 6.0
VALVE ACTUATOR
6.1
General The actuator shall be suitable for instrument air unless otherwise specified in the requisition. The actuator shall function properly under the minimum, normal and maximum instrument air supply pressures and process conditions as specified in the requisition. The following general requirements shall be applicable: The valve assemblies, including all ancillaries, shall have a minimum nominal design life of 20 years based on VENDOR's recommended maintenance procedures being followed during this period. For all actuated valves this shall correspond to a nominal minimum design limit of 1000 cycles. Materials of construction shall be suitable for achieving the above design life in a corrosive offshore or coastal environment. VENDOR shall specify in his quotation, materials of construction for all key components of the actuator assembly and ancillary equipment. Aluminium components shall not be specified for actuators or ancillary equipment. The actuator type shall be as specified in the requisition. In general actuator type selection shall be based on the following order of preference. Shutdown Valves and Blowdown Valves. (SDV's and BDV's) shall preferably utilise pneumatic, single acting, spring return actuators. Where space or torque limitations preclude the use of this type of actuator the following types may be specified. •
Hydraulic, single acting, spring-return;
VECO Doc. No. 20298-01-EJ12-022 Project Title
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•
Hydraulic, double acting;
•
Pneumatic, double acting.
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On loss of holding signal, or on loss of pneumatic/hydraulic pressure, SDV's shall revert to the closed position and BDV's shall revert to the open position. Accumulators for double acting actuators in SDV or BDV service shall be close coupled to the actuator. Alternatively the accumulator system may be shipped loose and located in a nonvulnerable area remote from the actuator providing that hydraulic/pneumatic supply and return lines to and from the actuator are suitably protected against fire/explosion damage. Actuators shall be sized to provide the following torque value based on the requirements of a new value, at all points of its operating cycle, from fully open to fully closed and viceversa. The required actuator torque shall be a minimum of 1.25 times the manufacturers maximum specified torque value at a pressure differential across the valve-equal to the full ambient temperature rated pressure of the valve. The valve torques shall be based on infrequent usage of approximately one cycle every 3 months. For SDV's, the above actuator torque shall be based on the specified minimum pneumatic or hydraulic supply pressure. For all valves the valve stem shall be sized such that it can not be subjected to torsional stresses in excess of that permitted by the valve manufacturer with the pneumatic/ hydraulic supply at its specified maximum pressure. These criteria shall also be applicable if the MAWP of the actuator body is below the maximum stated air supply pressure. The valve assembly shall be capable of being orientated in any direction with no external supports, Mounting details shall be such that no undue stresses are imparted to the actuator or valve shaft/body regardless of orientation. Pneumatic/hydraulic actuator bodies shall be of integral or all flanged/bolted construction. The use of pressure containing external tie bar construction shall not be permitted. For pneumatic and hydraulic actuators an adjustable restriction device shall be provided in the supply line to the actuator to enable the opening line to be adjusted. All actuators and ancillary equipment shall have a minimum ingress protection to IEC 60529, IP 65. The actual bench setting (spring range) shall be indicated on the valve tag plate. Actuators shall be designed for a minimum instrument air pressure of 3.5 bar (g), unless otherwise required. Actuators requiring an instrument air supply pressure above 3.5 bar (g) shall not be used unless approved by the COMPANY.
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The piston-type actuator, if specified, should be of the spring-opposed diaphragm or of the spring-opposed short-stroke type. Long-stroke springless piston actuators shall not be used. To prevent tampering, the rotating linkages between a butterfly valve and its actuator shall be of the integral type, enclosed in a protective metal housing. Cylinder actuators shall be provided with adjustable end-limit travel stops in both directions. Bolt adjustment type limit stops shall be fitted with a locking facility, e.g. a locking nut, to prevent tampering. The construction shall be leak-tight, with seal gaskets. Piston or cylinder actuators shall have O-ring sealing and shall be designed to minimize shaft and piston friction. Actuators shall be equipped with a direct-coupled adjustable travel or position indicator for local status indication. The position shall be indicated by a permanent mark on a reversible scale with the words 'open' and 'shut' at the travel limits, or by unambiguous symbols. The following additional requirements are applicable for pneumatic actuators: •
Pilot-operated valves for SDV's and BDV's shall, unless otherwise specified, be normally closed valves suitable for a-maximum supply and pilot pressure of 10 barg. Body material shall be 316SS and the valve shall be provided with a manual reset facility.
•
Pilot and solenoid operated valves for double acting actuators shall be generally as described above but shall be five port 4-way valves capable of alternately pressurising and venting each face of the power piston to open/close the valve as applicable.
•
Pneumatic tube and compression fittings shall be 316L Stainless Steel and shall be 10 mm OD x 1.50 mm wall thickness unless specified otherwise in the purchase requisition. Fittings shall be double ferrule type Swagelok or equal.
•
Unless specified to the contrary, accumulators for double acting actuators for SDV's shall be sized for three (3) strokes of the valve based on the specified normal and minimum pneumatic supply pressure.
•
Pneumatic actuators shall be configured such that they will hold open /closed against spring pressure at a minimum pressure of 3.5 barg.
The following additional requirements are applicable for hydraulic actuators: •
Hydraulic actuators may be double acting or hydraulic opening spring return type. In this context rotary vane type actuators shall be considered acceptable.
•
The design of the valve hydraulic system shall be generally in accordance with PTS 31.36.10.30.
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•
VENDOR may propose variations to-the PTS system configuration provided that these are highlighted in his bid for the systems with sufficient information to enable their acceptability to be evaluated.
•
Hydraulic pumps may be electrically or pneumatically operated. The pumps shall be provided with a manual stop/start facility and an auto start/stop facility to reestablish system pressure in the event that this should fall below an acceptable level.
•
The required capacity of the system accumulators shall be based on the pressure at which the hydraulic pumps auto start.
•
Unless otherwise stated in the purchase requisition one hydraulic hand pump shall be provided per system. The system shall be configured such that it shall not be possible to manually open the valve whilst the shutdown relay is in a deenergised state. No means of bypassing the shutdown system shall be provided.
•
The capacity of the hydraulic accumulators for central hydraulic systems shall be sufficient to provide three (3) strokes of the largest actuator connected to the system plus two (2) strokes of all other connected actuators. For a single valve system the accumulator(s) shall be sized for three (3) strokes of the valve.
•
All submissions shall include details of hydraulic pressures at pump start/stop points and upon completion of the specified number of valve strokes with the pressurising pumps in-operative .
Shutdown Valve Actuator In addition to the general requirements for the actuators(section 6.1), all ESD valves, and as specified On / Off valves, shall be fitted with fail safe, air driven, spring opposed, piston-type actuators. The use of any other type of actuator must first have COMPANY approval. An integral field ‘Open/Close’ indicator shall be included. This shall preferably be mounted on top of the actuator. Actuators shall be attached to the valve stem as per ISO 5211. ESD Valves shall not be fitted with hand wheels unless specified. The yoke shall be of the open type to allow access for adjustment of the packing gland follower. The actuator spring shall be fully enclosed in a metal housing and treated to resist atmospheric corrosion. The assembled actuator shall be designed to withstand (without damage) the mechanical design pressure of the Instrument Air System 10 barg. In order to facilitate proper installation of the actuator, the required mounting facility on the valves shall be designed and manufactured in consultation with the Supplier of the valve actuator. The design thrust or torque for actuator selection and all drive train calculations shall be at least twice the breakaway thrust or torque. However, when the valve is “running”, a minimum factor of safety of 1.25 times differential is obligatory between the maximum torque / thrust required to cycle the valve (with maximum differential pressure across the valve) and the output torque / thrust developed by the actuator, with air driven stroke of 3.5 barg, and spring driven stroke.
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Tensile stresses in the drive train components, including stem extensions, shall not exceed 67% of the specified minimum yield strength (SMYS) when delivering the design torque. Shear, torsion, and bearing stresses shall not exceed the limits specified in ASME Code Section VIII, Division 2, Part AD-132. If fireproofing has to be applied, accessories for ESD valves and actuators are protected from fireby installation inside protective local enclosures. The enclosures shall be rated for 30-minute fire rating without increasing internal temperature above the maximum allowable limit for the actuator and accessories. The box enclosure design shall have windows and apertures to provide visibility and access to accessories. The aperture shall be designed in such a way that accessories can easily be removable through this without removing the enclosure. In particular, the valve travel indicator shall be extended outside enclosure. 6.2.1
Actuator Material ESD valves actuators shall be made preferably of steel, aluminum actuators shall not be used.
6.3
Stroking Time Unless other stroking times are indicated in the requisition, the following stroking times for both directions are required: •
1 second per inch of nominal size with a maximum of 45 seconds.
If faster stroking times are required, high capacity valve positioners should be considered. If these are not available, then additional boosters or quick-exhaust valves shall be installed. Valves used for on/off service (e.g. ESD valves, or control valves with a trip function) shall have a stroking time as indicated on the P&ID’S or in the requisition or instrument data sheet. If air pressure is used to close the valve under emergency conditions or to assist the spring force, the size of the air signal line and fittings and the air capacity of the accessories shall be designed to ensure the specified stroking time. The effect of stroking time on the pressure build-up in liquid-filled lines (hydraulic shock or water hammer) should be checked. Similarly, to prevent shock-loading of process equipment downstream of fail-closed shutoff valves, a special design may be required to ensure controlled (re-)opening of these valves. The stroking times are applicable to the valve with accessories, e.g. solenoid valves, etc. 6.4
Actuator Colour Coding The colour of the actuator shall be in accordance with the painting specification number 12-MGDP-P-1005 unless otherwise specified in the requisition or by COMPANY. To
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identify the valve fail-safe position, a colour code may be given to the actuator (e.g. red for spring closing valves and green for spring opening valves), as specified in the requisition. 7.0
ACCESSORIES
7.1
Hand Wheels Shutdown valves shall not be provided with a hand wheel unless shown on the P&ID’s. If a hand wheel is required, the following shall apply:
7.2
•
The hand wheel shall be of an all-metal design;
•
The hand wheel shall be provided with position indicators;
•
The operating force, under maximum design conditions, shall not exceed 350 N on the rim of the hand wheel;
•
The changeover from actuator operation to hand wheel operation shall be possible in all stem positions;
•
The hand wheel shall be of lockable type.
Lock-up Valves Air lock-up valves shall be specified for the following applications: •
All shut-off valves requiring an air supply pressure higher than the guaranteed minimum instrument air pressure.
The lock-up valves shall have a bolt adjustment provided with a locking facility, e.g. a locking nut, to prevent unintentional adjustments. The lock-up valves shall be set 0.5 bar above the required valve air supply pressure unless some other set value is required for a particular actuator. For lock-up valves fitted on valves operated by a solenoid valve, this solenoid valve shall be installed between the lock-up valve and the actuator. 7.3
Limit Switches "Open" and/or "close" limit switches shall be fitted only if shown on the P&ID’s. When specified in the purchase requisition, the valve/actuator assembly shall be provided with electrical limit switches which will indicate when the valve is either in the fully open or fully closed position. If fitted, the external linkage between the actuator stem or rotary spindle and the initiator shall be protected against unintentional damage. Protection shall be to IEC-60529, IP65 and the switches shall be suitable for inclusion in an intrinsically safe circuit. Proximity switches shall be configured such that metal is detected when the end position is reached. Mechanically operated switches shall be configured such that the contacts are open when the valve is in the appropriate fully open or fully closed position and closed when the valve is stroking.
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Limit switches shall be proximity type (preferred) or mechanically operated hermetically sealed rated for 0.5A at 24V DC and shall terminate in an attached junction box; alternatively, the protection box and the junction box may be combined into one box. The switches shall be SPDT and shall utilise a 20mm ISO single electrical entry. Proximity switches shall be of dry-contact type. NAMUR type switches are not acceptable. The Junction boxes shall be suitable for the electrical hazardous area classification in which they are located. If not armoured, the flying leads shall be protected by a flexible conduit. Proximity switches shall be adjustable and shall function autonomously, e.g. one switch for the "fully open" position and a separate switch for the "fully closed" position. The combination of proximitor and proximitor circuit shall be of fail-safe design. The mounting instructions supplied by the limit switch VENDOR shall be followed by the valve VENDOR. The limit switches shall be properly adjusted by the valve VENDOR. 7.4
Air Lubricators It is required that air cylinder and piston material shall be such that no external lubrication supply is necessary. However if the application demands air lubricators (if approved by the COMPANY) shall be of the oil-mist type and the oil flow shall be externally adjustable. The oil buffer capacity shall be sufficient for continuous operation for one month. In addition, the lubricator shall have facilities for oil refilling under pressure, shall have oil level indication and shall be suitable for installing on a mounting plate. Where air lubricators are used for valves operated by a solenoid valve, the lubricator shall be installed upstream of the solenoid valve. Air lubricators shall be considered for pneumatic long-stroke cylinder actuators. Spherical glass (bowl type) air lubricators shall not be used.
7.5
Solenoid Valves For emergency shut-off valves, the solenoid valve shall be installed directly on the valve actuator. Solenoid valves should be direct-operated; the use of pilot-operated solenoid valves shall be subject to the approval of the COMPANY. The capability of the solenoid valve (e.g. capacity, pressure rating) shall be checked against the instrument air requirement of the particular actuator. Solenoid valves shall be 24VDC, low wattage (6 watts) with class F insulation. Body shall be 316 SS. Body rating shall be a minimum of 10 barg; a manual reset facility shall be provided, solenoid valve for SIS loop shall be SIL-3 certified. Flying leads are not acceptable. Solenoid valve shall be provided screw type terminals with M20 cable entry for electrical connections.
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Electrical certification shall be as per specified in the datasheet but minimum EEx 'i' llA T3 with protection to IP 65. To prevent high voltage induction, solenoid valves operating on direct current shall be provided with reverse diodes. The solenoid valves shall be provided with a disc and/or seat of resilient material to achieve TSO. The air passages in the solenoid valves shall be large enough to achieve the opening or closing time of the valve as specified. If this would lead to unrealistically large passages and consequently high power consumption of the solenoid valve, consideration should be given to the use of quick-exhaust valves. The minimum port size in the solenoid valve shall be stated by the solenoid valve VENDOR and this shall be taken into account in the stroking time calculations.Solenoid valves shall be not be supplied with exhaust port protectors but, to prevent plugging, shall be provided with a piece of tubing bent downwards, with the end cut off at an angle of 45 degrees. Ambient temperatures, including the effects of direct sunlight, shall be specified and the solenoid valve selected accordingly. 7.6
Filter Regulators If the maximum air supply pressure is greater than the operating pressure of the actuator or its accessories, or if the valve positioner needs a regulated air pressure, then an air filter regulator shall be installed in the instrument air supply line. The make of filter regulator shall be as specified in the requisition. The air filter regulators shall be of the reducing-relief valve type, with drainage facility and bolt adjustment provided with a locking facility, e.g. a locking nut, to prevent tampering. Air filter regulator shall be 316SS body with 316SS output gauge. The air filter cartridges shall be of the rigid structure type to resist channelling, rupturing, shrinkage or distortion and shall have a maximum mesh size of 40 mm. The capability, e.g. output capacity and required spring range, of the filter-regulator shall be checked against the instrument air requirement of the particular actuator or pneumatic instrument. Glass (bowl-type) filter regulators shall not be used. Filter regulators shall be mounted vertically so that they are self-draining. If the actuator is capable of withstanding full instrument air pressure (specified maximum design condition of the instrument air supply system), no regulator shall be installed, only a filter.
7.7
Filters If a filter regulator is not installed an air filter shall be installed in the instrument air supply line to the valve. The air filter shall be provided with a manual drainage facility and a filter
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cartridge of the rigid structure type, to resist channeling, rupturing, shrinkage or distortion, and having a maximum mesh size of 40 micron. Glass (bowl type) filters shall not be used. Filters shall be mounted vertically so that they are self-draining. 7.8
Volume Boosters Volume boosters shall only be provided if needed to achieve the specified stroking times. Volume boosters for pneumatic actuators shall be of the high capacity type with fast throttling to control the required capacity.
8.0
VALVE IDENTIFICATION The valve shall be provided with a standard stainless steel identification plate. At least the following information shall be clearly stamped on the plate: •
Manufacturer's name or trademark.
•
Manufacturer's model/type number (valve and actuator).
•
Manufacturer's serial number.
•
Body pressure rating.
•
Size (body and trim/ Cv value).
•
Material (body and trim).
•
Type of plug (characteristic).
•
Bench setting or spring range.
•
Action on air supply and/or signal failure.
In addition, each valve shall be provided with a stainless steel tag plate, which shall be fixed to the valve with a stainless steel wire. This plate shall be marked with the COMPANY's tag number as stated in the requisition. Valves shall be marked in accordance with the applicable design code. The direction of flow, the valve body rating, the body material and, where applicable, the TSO direction(s) shall be clearly indicated by a permanent mark cast in or stamped on the valve body, not painted. The valve tag number shall be stamped on the valve body or flange if the identification plate is attached to the actuator. Warning plates shall be fixed by screws or rivets. 9.0
INSPECTION AND TESTING
9.1
Extent The VENDOR shall perform the following inspections and tests (see Note 1):
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Dimensional inspection Hydrostatic test Functional test Seat leakage test
All valves All valves All valves Valves with Class V All valves or Class VI shut-off requirements
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Method and Acceptance criteria (9.2) (9.3) (9.4) (9.5)
Notes:
9.2
1
The specified extent and acceptance criteria shall be in accordance with the VENDOR's standard where more frequent or stringent.
2
The number of valves sampled shall be subject to the approval of the COMPANY.
3
The selected valves for each test shall be listed by the VENDOR and approved by the COMPANY.
4
Inspection and testing shall include accessories if part of the supply.
5
The test results shall be made available to the COMPANY as part of the package of final certified documents and drawings.
6
Hydrogen service means all process conditions with a hydrogen partial pressure greater than 7 bar (abs).
Dimensional and Flange Face Finish Check The face-to-face dimensions of flanged body valves shall be as given in the relevant standard refer section 4.4. All dimensions (including overall height) shall be as shown on the VENDOR's drawings. The flange face finish shall be checked.
9.3
Hydrostatic Test Hydrostatic testing shall be in accordance with API 6D at test pressure or better, with the test duration as follows: Valve size
Test Duration
≤ 2”
1 minute
3” to 8”
2 minutes
≥ 10”
3 minutes
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Functional Test The shutdown valve shall be completely assembled and fitted with all equipment such as actuator solenoid valve(s), etc. The stuffing box shall be correctly packed and soap tested with 3.5 bar(g) air pressure inside the valve body. All required stroking times shall be checked. If the valve is equipped with limit switches, they shall be checked for functional operation with a proximity tester.
9.5
Seat Leakage Test The seat leakage test shall be in accordance with API 598 / 6D Zero Leakage. For each valve tested, the VENDOR shall state the following data:
10.0
•
Flow direction;
•
Test medium;
•
Test differential pressure;
•
Seat leakage flow rate measured;
•
Allowable seat leakage flow rate;
•
Seat leakage class.
MATERIALS AND INSPECTION CERTIFICATION Materials and inspection certificates shall be provided by Vendor.
11.0
WITNESSING BY ENGINEER/ COMPANY The extent of the COMPANY's involvement in witnessing inspections and tests at the VENDOR's works shall be minimized and shall be specified on the requisition. Upon request, a quality plan shall be submitted by the valve VENDOR.
12.0
PROTECTION AND PACKAGING All necessary precautions shall be taken for adequate protection of the valves, including accessories, during shipment and outdoor storage at their destination. These precautions shall include the following: •
Before leaving the factory, all openings in the valve body shall be provided with temporary closures to prevent entry of dirt or other materials.
•
During transport and storage, the valve ends shall be protected with suitable close fitting protectors (e.g. plastic caps) or covers of at least 3 mm thick and securely fastened by an adequate number of bolts.
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•
Open threaded connections, e.g. air connections of actuators, positioners and accessories, shall be fitted with thread protectors to prevent the ingress of moisture.
•
The stuffing boxes of valves with graphite-based packing shall be protected against the ingress of moisture.
DOCUMENTATION The VENDOR shall submit the following documents with the quotation: •
Details of the selected actuator and torque figures.
•
Calculations of the predicted noise level, and, where applicable, details of the secured instrument air vessel.
•
Dimensional outline drawing of the shutdown valve, including accessories, air lines and, where applicable, the secured air vessel.
•
Details of where the full valve specifications will be held.
The results of the inspections and tests by the VENDOR shall be made available to the COMPANY as part of a package of final certified documents and drawings. The VENDOR shall complete a spare parts list and interchangeability record (E-SPIR) for all equipment supplied. See PTS 70.10.90.11. Vendor shall also comply with the requirements of documentation specified in PCPL procedure CSP-03.
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