COMPLETE REVISION May Process Industry Practices Piping. PIP PNSM0110 Purchasing Requirements for Valves

Transcription

1 May 2013 Process Industry Practices Piping Purchasing Requirements for Valves

2 PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES In an effort to minimize the cost of process industry facilities, this Practice has been prepared from the technical requirements in the existing standards of major industrial users, contractors, or standards organizations. By harmonizing these technical requirements into a single set of Practices, administrative, application, and engineering costs to both the purchaser and the manufacturer should be reduced. While this Practice is expected to incorporate the majority of requirements of most users, individual applications may involve requirements that will be appended to and take precedence over this Practice. Determinations concerning fitness for purpose and particular matters or application of the Practice to particular project or engineering situations should not be made solely on information contained in these materials. The use of trade names from time to time should not be viewed as an expression of preference but rather recognized as normal usage in the trade. Other brands having the same specifications are equally correct and may be substituted for those named. All Practices or guidelines are intended to be consistent with applicable laws and regulations including OSHA requirements. To the extent these Practices or guidelines should conflict with OSHA or other applicable laws or regulations, such laws or regulations must be followed. Consult an appropriate professional before applying or acting on any material contained in or suggested by the Practice. This Practice is subject to revision at any time. Process Industry Practices (PIP), Construction Industry Institute, The University of Texas at Austin, 3925 West Braker Lane (R4500), Austin, Texas PIP member companies and subscribers may copy this Practice for their internal use. Changes or modifications of any kind are not permitted within any PIP Practice without the express written authorization of PIP. Authorized Users may attach addenda or overlays to clearly indicate modifications or exceptions to specific sections of PIP Practices. Authorized Users may provide their clients, suppliers and contractors with copies of the Practice solely for Authorized Users purposes. These purposes include but are not limited to the procurement process (e.g., as attachments to requests for quotation/ purchase orders or requests for proposals/contracts) and preparation and issue of design engineering deliverables for use on a specific project by Authorized User s client. PIP s copyright notices must be clearly indicated and unequivocally incorporated in documents where an Authorized User desires to provide any third party with copies of the Practice. PRINTING HISTORY February 1999 Issued April 2006 Complete Revision June 2001 Technical Correction May 2013 Complete Revision Not printed with State funds

3 May 2013 Process Industry Practices Piping Purchasing Requirements for Valves Table of Contents 1. Introduction Purpose Scope References... 2 Industry Codes and Standards Definitions Requirements General Materials of Construction Design Testing, Inspection, and Repair Surface Preparation and Coating Engineering Data Requirements Identification Shipping, Handling, and Storage Examination by Purchaser Process Industry Practices Page 1 of 11

4 1. Introduction 1.1 Purpose This Practice provides purchasing requirements for valves. 1.2 Scope This Practice describes the minimum requirements for the procurement of valves listed in the PIP Line Class Material Specifications and PIP Valve Descriptions. 2. References Applicable parts of the following industry codes and standards shall be considered an integral part of this Practice. The edition in effect on the date of contract award shall be used, except as otherwise noted. Short titles are used herein where appropriate. Industry Codes and Standards American Petroleum Institute (API) API 594 Check Valves: Flanged, Lug, Wafer and Butt-welding API 598 Valve Inspection and Testing API 599 Metal Plug Valves Flanged, Threaded and Welding Ends API 600 Steel Gate Valves - Flanged and Butt-welding Ends, Bolted Bonnets API 602 Steel Gate, Globe, and Check Valves for Sizes NPS 4 and Smaller for the Petroleum and Natural Gas Industries API 607 Fire Test for Soft-Seated Quarter- Turn Valves API 608 Metal Ball Valves Flanged, Threaded and Welding Ends API 609 Butterfly Valves: Double Flanged, Lug- & Wafer- Type API 6FA Specification for Fire Test for Valves API 6D Specification for Pipeline Valves American Society of Mechanical Engineers (ASME) ASME Boiler and Pressure Vessel Code Section IX Welding and Brazing Qualifications ASME B1.1 Unified Inch Screw Threads (UN and UNR Thread Form) ASME B Pipe Threads, General Purpose (Inch) ASME B16.5 Pipe Flanges and Flanged Fittings NPS 1/2 through NPS 24 ASME B16.11 Forged Fittings, Socket-Welding and Threaded ASME B16.25 Buttwelding Ends ASME B16.34 Valves Flanged, Threaded, and Welding End ASME B16.47 Large Diameter Steel Flanges (NPS 26 through NPS 60) ASME B31.3 Process Piping ASME B36.10M Welded and Seamless Wrought Steel Pipe Process Industry Practices Page 2 of 11

5 3. Definitions ASME B36.19M Stainless Steel Pipe Manufacturers Standardization Society (MSS) MSS SP-25 Standard Marking System for Valves, Fittings, Flanges and Unions MSS SP-45 Bypass and Drain Connections MSS SP-53 Quality Standard for Steel Castings and Forgings for Valves, Flanges and Fittings and Other Piping Components-Magnetic Particle Exam MSS SP-54 Quality Standard for Steel Castings for Valves, Flanges and Fittings and Other Piping Components - Radiographic Examination Method MSS SP-55 Quality Standard for Steel Castings for Valves, Flanges and Fittings and Other Piping Components Visual Method for Evaluation of Surface Irregularities MSS SP-80 Bronze Gate, Globe, Angle and Check Valves manufacturer: Party responsible for making the valves new valve: Unused valves from the original manufacturer through the supplier and received by purchaser without modifications by parties other than the original manufacturer or other third party organizations approved by purchaser purchaser: Party that awards the contract to the supplier. The purchaser may be the owner or owner s authorized agent. supplier: Party responsible for furnishing and/or installing the valves valve purchase descriptions: Within the scope of this Practice, this term refers to the purchase order, the valve descriptions attached to this specification, and the requirements of this specification 4. Requirements 4.1 General The valve purchase specifications detailed in this Practice shall be used in the purchase and specification of new valves. Any substitution to or variance from this Practice shall be approved in writing by purchaser before implementation Codes, standards, and specifications referred to in this Practice, in the valve purchase descriptions, or in any referenced document form a part of the requirements of this specification in the manner and to the extent specified Modifications shall not be performed on a valve to bring it into conformance with the valve purchase description without the written approval of the purchaser Modification to a valve shall maintain the manufacturer s warranty. 4.2 Materials of Construction Materials shall be as specified in the valve purchase descriptions. All materials shall be new and unused. Process Industry Practices Page 3 of 11

6 4.2.2 Consideration shall be given to pressure/temperature limitations of secondary materials not specifically identified (e.g., soft sealing materials) Substitution of castings in which pressure-retaining parts have been specified as forged shall not be permitted without the written approval of the purchaser Substitution of alternate materials for materials specified on the purchase order or in the valve purchase description shall not be permitted without the written approval of the purchaser Bonnet bolting material shall be in accordance with the valve design standard Rubber and plastic components in contact with process fluid shall be manufactured from virgin materials. Reprocessed materials shall not be permitted Lubricants with a viscosity greater than kerosene shall not be used in the assembly of internal wetted components, including the stems of valves without approval of the purchaser. 4.3 Design Codes and Standards Valve design shall be in accordance with the latest revision of the standard specified in the valve purchase description Pressure-Temperature Ratings Valve pressure-temperature ratings shall be in accordance with ASME B16.34 or the referenced standard. Comment: Certain types of valves (butterfly, ball, diaphragm, etc.) may not conform entirely to ASME B16.34 pressuretemperature ratings If requested in the purchase order, information on pressure-temperature ratings shall be submitted for approval by the purchaser Butt-Welding End Valves Weld bevel and end preparation for butt-welding end valves shall be in accordance with ASME B a. Carbon and alloy steel valves shall be in accordance with ASME B16.25, Figures 2 and 3. b. Stainless steel, nickel, and nickel alloy valves shall be in accordance with ASME B16.25, Figures 4, 5, and If necessary to furnish butt-welding end valves with ends internally taper-bored to match the specified schedule (weight or thickness), endto-end (or center-to-end for angle valves) dimensions (in inches) shall be furnished if tapering results in nonstandard end-to-end (or center-to-end) dimensions. This information shall be submitted as part of the quotation The bore of butt-welding end valves specified as Schedules 10, 20, 30, 40, 60, 80, 100, 120, 140, or 160 (without the suffix S ) and standard, extra strong, or double, extra strong shall be in accordance with ASME B36.10M. Process Industry Practices Page 4 of 11

7 The bore of butt-welding end valves specified as Schedules 5S, 10S, 40S, and 80S shall be in accordance with ASME B36.19M Flange Finish Unless otherwise specified in the valve purchase description or purchase order, the finish for gasket contact faces of flanged ends shall be in accordance with ASME B16.5/B Scratches or other damage to gasket contact surfaces greater than permitted in accordance with ASME B16.5/B16.47 shall not be permitted Valve Operators Unless otherwise specified in the valve purchase descriptions, operators shall be designed to function with a maximum 360 Newton (80 lbf) total rim force on the operator at a differential shut-off pressure equal to 100 percent of full pressure rating at 38ºC (100ºF) rating across the valve Manually operated valves shall be provided with individual levers, wrenches, handles, or handwheels. All levers, wrenches, handles, and handwheels shall be made of ductile iron or steel and coated or painted Gear operated valves shall be provided in accordance with the following: a. Gear operators shall be weatherproof. b. Gear operator position shall be rotatable a minimum of 90 degrees. c. The valve manufacturer or manufacturer s authorized distributor shall install gear operators Valve Body Tappings Location of valve body tappings, if specified, shall be in accordance with ASME B16.34, Figure 1, or MSS SP Tappings having female taper pipe threads in accordance with ASME B shall be fitted with solid forged plugs. These plugs shall be in accordance with ASME B16.11 and be of the same basic metallurgy as the valve body material Tappings having socket-welding openings shall be in accordance with ASME B16.34, Paragraph 6.3.3, and shall be fitted with plastic plugs The valve purchase description shall state tapping connection type and orientation Ball and Plug Valves Ball valves with resilient seats shall have electrical continuity in accordance with API Sleeve-lined plug valves shall have electrical continuity in accordance with API Electrical resistance shall not be greater than 10 ohms for either ball valves with resilient seats or sleeve-lined plug valves. Process Industry Practices Page 5 of 11

8 Ball valves having the ball extending outboard of the valve ends shall not be permitted without the approval of the purchaser Pressure Relief of Valve Cavity Valves may be required to have the high-pressure face (if closed) of the ball (plug, wedge, etc.) drilled to relieve fluid trapped in the valve cavity. If this is a requirement of the valve purchase description, the high-pressure side of the valve body shall be stamped Threaded Tapped Holes Threaded tapped holes in valve bodies, if required for bolting to external flanges, shall be in accordance with ASME B Markings for Flow Direction Globe valves shall be marked by a permanent means with a flow arrow or bridge wall marking to indicate the direction of flow, which results from pressure under the valve seat or disc. The preferred method of marking is for arrows to be cast or forged into the valve body Check valves and other valves with unidirectional flow shall be marked by a permanent means with a flow arrow to indicate the direction of flow Use of stamping or other marking method shall not affect the required pressure thickness. Stamping shall be with low stress steel stamps Extended Bonnet Valves Stems for extended bonnet valves for cryogenic service shall be made of one piece only. Welded stems and stems of two or more pieces shall not be permitted Extended bonnets shall be designed to permit the valve to be installed with the stem in the vertical position or within 45 degrees of vertical without risk of leakage or seizure Blowout Proof Stems/Shafts The stem or shaft shall be designed so that if failure of the stem-to-disc, failure of the shaft-to-disc, or internal failure of the stem or shaft occurs, no portion of the stem or shaft can be ejected from the valve as a result of internal pressure. 4.4 Testing, Inspection, and Repair Pressure Testing Unless otherwise specified in the standard to which the valves are manufactured, all valves shall be pressure tested in accordance with API Standard 598 as a minimum Pressure testing shall not be conducted through a connection in the bonnet of a valve Pressure testing of austenitic stainless steel valves shall be in accordance with the following: Process Industry Practices Page 6 of 11

9 a. Water having less than 50 ppm chloride content shall be used for pressure testing. b. After pressure testing, test water shall be immediately drained and valves shall be dried by blowing with oil-free dry air or dry nitrogen (-29 C (-20 F) dew point) at a temperature not greater than 60 C (140 F) The type or style of valve stem packing (or seals) used during pressure testing shall be the same as that specified to be provided with the valve Inspection Each valve shall be given both an in-process and final inspection by the manufacturer Inspectors shall review all internal and external surfaces of each valve for the following features: Repairs a. Steel surfaces shall be in accordance with MSS SP-55. b. Stems shall be free of scratches, dents, or other types of damage. c. Welds shall be visually checked to be in accordance with ASME B31.3, Table , for normal service. d. Threads shall be free of defects or damage Casting repairs shall be made in accordance with the ASTM specification to which the casting was procured Repair of castings by impregnation with metallic or nonmetallic materials shall not be permitted Repairs shall not be permitted on cast iron, ductile iron, or bronze valves. 4.5 Surface Preparation and Coating Unless otherwise specified, austenitic stainless steel, nickel-based alloy, and nonferrous valves shall not be painted Unless otherwise specified, all external surfaces of ferritic valves shall be prepared, primed, and/or painted in accordance with the manufacturer s standard procedure. 4.6 Engineering Data Requirements Certified Drawings If requested by the purchaser, certified dimensional drawings shall be provided that show the following information: a. End-to-end dimensions b. Center line to the top of the valve stem or operator dimensions in both the open and closed positions c. Weight of individual valves (including weight of operators) Process Industry Practices Page 7 of 11

10 4.6.2 Welding Procedures Welding Procedure Specifications (WPS) and Procedure Qualification Records (PQR) shall be in accordance with ASME Boiler and Pressure Vessel Code, Section IX Individual WPS and PQR shall be available for examination by the purchaser upon request If specified on the purchase order, a WPS and a PQR shall be submitted to the purchaser for approval before the start of manufacturing Material Certification This section shall apply to all valves with body and bonnet material specified to an ASME (SA or SB) specification If requested by purchaser, the manufacturer s certificate of compliance with the referenced ASME specification for the body and bonnet shall be provided The certification shall also state compliance with applicable ASME specifications for the bonnet bolting If required by purchaser, these documents shall be identified with the purchaser s purchase order number and valve tag number and shall be signed by the manufacturer s authorized agent ASTM materials may be substituted for materials specified as ASME if the ASME specification is indicated (below the title) to be identical with the corresponding ASTM specification for the grade, class or type produced The manufacturer shall state the dual compliance on the certificate of compliance ASTM specification substitutions shall be submitted for approval by purchaser before processing the purchase order Material Test Reports If requested by purchaser, the manufacturer s Material Test Reports for the body and bonnet that show actual results of chemical analyses and mechanical tests in compliance with the referenced ASTM specification shall be furnished The test reports shall be traceable to each valve production lot The test reports shall be identified with the purchaser s purchase order number and shall be signed by the manufacturer s authorized agent If required by purchaser, impact testing shall be in accordance with the requirements of ASME B31.3, Paragraph Results shall be recorded on the manufacturer s Material Test Reports Installation Instructions The manufacturer s instructions for installation, welding, and postweld heat treatment for all socket-welding and butt-welding end valves shall be provided. Process Industry Practices Page 8 of 11

11 If required by purchaser, instructions for disassembly and reassembly of valves shall be provided If disassembly of valves is required, a list of the manufacturer s recommended replacement parts shall be provided If a manufacturer does not require special procedures, a written certification to this effect shall be provided with the valves Other Manufacturer Documents 4.7 Identification For all valves not manufactured in accordance with a national standard, both the maximum allowable hydrostatic shell and closed-seat test pressures that valves can be subjected to during field pressure testing shall be provided If requested by purchaser, the following procedures shall be provided: a. Bolted joint connection (i.e., bolting pattern and torque) b. Cleaning c. Field installation d. Final inspection e. Heat treatment f. In-process inspection g. Marking h. Nondestructive examination i. Packing j. Painting k. Pressure testing l. Repair m. Shipping n. Supplemental high-pressure testing o. Tagging p. Valve assembly q. Welding The procedures shall be written such that a person familiar with the type of work described can complete the task by following instructions in the document If engineering data other than that listed in this Practice is required by the purchaser, a statement of those requirements shall be included in the request for quotation and/or purchase order Manufacturer s Markings Each valve shall be marked in accordance with ASTM material specifications, valve design standards, and MSS SP-25. Process Industry Practices Page 9 of 11

12 Valves manufactured with dual-certified materials shall have both material designations shown Forgings or castings not marked in accordance with their applicable ASTM standards shall not be permitted Valve Tagging Guidelines Each valve shall be tagged with the purchaser s valve tag number that accurately represents the valve Valve tags shall be configured as follows: a. Tags shall be 28-gauge (minimum) stainless steel or a corrosionresistant material providing equivalent visibility and durability. b. Letter and number heights shall be a minimum of 4.5 mm (3/16 inch). c. Tags shall be attached with 16-gauge minimum stainless steel wire or equivalent. d. Tags attached to valve handles shall not be permitted. e. Tags shall be attached in a manner that does not interfere with the installation or operation of the valves If specified on the purchase order, each valve shall be tagged with a separate tag showing the valve packing material/type All marking shall be clearly legible Valves not properly tagged shall not be permitted. 4.8 Shipping, Handling, and Storage Valves shall be shipped in a cardboard box, in a wooden crate, or on a wooden pallet and shall be packed to prevent shifting within the container Valves shall be shipped with the correct stem packing installed and the gland follower tightened Closure positions for valves for shipment shall be as follows: a. Gate and globe valves shall be shipped in the closed position. b. Plug and ball valves shall be shipped in the open position. c. Butterfly valves shall be shipped with the disc cracked open (i.e., off the seat) Check valves that have blocking between the seat and piston/disk/ball to prevent in-transit damage to the seat shall be tagged to indicate that blocking is installed. The tag shall indicate that the blocking is required to be removed before installation. The manufacturer shall be responsible for determining if valves require blocking Threaded or socket-welded openings shall be closed with metal or plastic protectors to prevent dirt and other foreign matter from entering the interior of the valve. Process Industry Practices Page 10 of 11

13 4.8.6 Flange facings and butt-welding ends shall be protected for shipment as follows: a. The entire gasket seating surface or butt-welding end shall be covered with wood, plastic, or metal covers. b. The protection covers shall prevent dirt and other foreign matter from entering the interior of the valve and damaging the flange facings or buttwelding bevels. c. If flange facings or butt-welding bevels are protected with metal covers, a layer of nonmetallic material shall be provided between the valve and the cover. d. Tape shall not be used as the sole covering method Valves shall be prepared for shipment in a manner that avoids damage to or atmospheric corrosion of internal or external surfaces or parts during sheltered storage and transport If required by purchaser, outdoor storage shall be indicated in the valve purchase description Padded slings, cables, chains, or bands shall be used to prevent damage to valves during handling and transportation Unless otherwise specified, machined or threaded surfaces of ferritic valves shall be coated with an easily removable, rust-preventive compound. For valves that have been cleaned for special service, rust-preventive compounds shall not be permitted If specified in the purchase order, austenitic stainless steel valves shall be enclosed by wrapping in a vapor-proof barrier material. 4.9 Examination by Purchaser Inspection and/or tests shall be reviewed and/or witnessed by the purchaser at the supplier s or the manufacturer s facility at a mutually convenient time. Process Industry Practices Page 11 of 11