GSPC GAS COMPANY LIMITED

CITY GAS DISTRIBUTION PROJECT

CLIENT JOB NO.

TECHNICAL SPECIFICATION
FOR
BALL VALVES
DOCUMENT NO

11

0299

TOTAL SHEETS

02

08

16

02

003

06/02/10

ISSUED FOR TENDER

AS

DDS

PKS

04/02/10

ISSUED FOR IDC

AS

DDS

PKS

REV

DATE

DESCRIPTION

PREP

CHK

APPR

TABLE OF CONTENT

1.0

SCOPE .............................................................................................................................3

2.0

REFERENCE DOCUMENTS ...........................................................................................3

3.0

DEFINITIONS ...................................................................................................................4

4.0

INSTRUCTIONS ...............................................................................................................5

5.0

MATERIALS .....................................................................................................................5

6.0

DESIGN AND CONSTRUCTION ....................................................................................6

7.0

INSPECTION AND TESTS ...........................................................................................10

8.0

TEST CERTIFICATES ...................................................................................................12

9.0

PAINTING, MARKING AND SHIPMENT......................................................................12

10.0

SPARES AND ACCESSORIES....................................................................................13

11.0

DOCUMENTATION

13

ANNEXURE A

DATA SHEET

ANNEXURE B

QUALITY ASSURANCE PLAN

ANNEXURE C

PIPING MATERIAL SPECIFICATION

TECHNICAL SPECIFICATION
FOR
BALL VALVES

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1.0

SCOPE
This specification provides minimum requirement for design, manufacturing, Inspection, Testing and
supply of Carbon steel Ball Valves covering sizes NB through 36NB( 900mm) for ANSI pressure
classes # 150 through # 900 to be used in cross country Gas pipeline(onshore) and City Gas distribution
for handling non-sour hydrocarbon in liquid or gaseous phase.

2.0

REFERENCE DOCUMENTS
The following Standard includes provision which, through reference in this text constitute provision of this
Standard. Latest revision of this standard shall be used unless otherwise specified.

API 6D

Specification for Pipeline Valves.

API 605

Large Diameter Carbon steel Flanges.

API 6FA

Specification for Fire Test for Valves.

API 5L

Specification for Line Pipe.

API 1104

Specification for Welding Pipelines and related facilities.

ASME 16.10

Face to Face and End to End Dimensions of Valves

ASME 16.20

Metallic gasket for pipe flanges Ring joint or spiral wounds and
jacketed.

ASME 16.21

Non Metallic Gaskets for pipe flanges.

ASME B 16.5

Steel Pipe Flanges and Flanged Fittings.

ASME B 16.34

Valves - Flanged, Threaded and Welding Ends.

ASME B 16.5

Steel Pipe Flanges and Flanged Fittings.

ASME B 31.3

Process Piping.

ASME B 31.8

Gas Transmission and Distribution Piping Systems.

ASME Sec VIlI Div.I/Div.II :

Boiler and Pressure Vessel Code Rules for Construction of

Pressure Vessels.

ASTM A370

Standard Test Methods and Definitions for Mechanical Testing of Steel

Products.

ASTM B 733

Auto catalytic Nickel Phosphorous Coating on Metals.

BS 6755-1

Testing of Valves. Specification for production pressure testing

requirements.

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EN 1004511

Metallic products: Charpy Impact

test test methods (U & V Notches)

BS 6755-2

Testing of Valves. Specification for fire type-testing requirement.

EN 10204

Metallic Materials Types of Inspection documents.

MSS-SP-6

Standard Finishes for Contact Faces of Pipe Flanges and Connecting end Flanges of Valves and Fittings.

MSS-SP-25

Standard marking system for Valves, Fittings, Flanges and Union.

MSS-SP-44

Steel Pipeline Flanges.

MSS-SP-53

Quality Std for Steel Casting & Forgings for Valves, Flanges & Fittings &
Other Piping Components Magnetic Particle Examination Method.

MSS-SP-55

Quality Standard for Steel casting of valves, Flanges, Fittings & other
Piping components (Visual Method)

MSS-SP-72

Ball Valves with Flanged or Butt welding ends for General Service.

ISO 5208

Industrial Valves Pressure Testing of Valves

ISO 10497

Testing of Valves fire type testing requirements.

ISO 13623

Petroleum & Natural Gas Industry pipeline transportation system.

ISO 14313

Petroleum & Natural Gas Industry. Pipeline transportation system

pipeline Valves

SSPC-VIS-1

Steel Structures Painting Council Visual Standard.

In case of contradiction the most stringent shall apply.

3.0 DEFINITIONS
Purchaser

: The Company which makes purchase order.

Manufacturer

: Manufacturer who receives the purchase order.

Shall

: This verbal form indicates requirements strictly to be followed in order to confirm to the
standards and from which no deviation is permitted.

Should

: This verbal form indicates that among several possibilities one is particularly suitable
without mentioning or excluding others or that a certain course of action is preferred
but not necessarily required.

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May

: This verbal form indicates a course of action permissible within the limits of this
standard.

Can

: This verbal form used for statements of possibility & capability, whether material,
physical or casual.

4.0

INSTRUCTIONS

4.1

Eventual Interpretations and deviations to this specification by the manufacturer shall be

requested by writing in his offer with detailed justification and approved by the purchaser or
purchasers representative before the eventual order to the manufacturer.

4.2

The specifications of the steel used shall be mentioned by the material manufacturer and all
potential sub contractors (such as forging plant, casting plant and fabrication unit etc) will be
described in the offer. After order no change will be accepted except for justified. In that case the
asked changes shall be supported by a technical file submitted to the purchaser and the
purchasers representative for approval.

4.3

The manufacturer shall provide a technical description of the manufacturing methods that might
influence the quality of material.

4.4

The purchaser/ purchasers representative keeps the right to audit the manufacturers and sub
contractors manufacturing and control methods. All costs for such an audit shall be borne by the
manufacturer except the wages, travel expenditure, lodging and boarding of the auditors
supported by the purchaser/ purchasers representative.

4.5

The purchaser/ purchasers representative shall have at any time free access to all parts of the
manufacturers facilities and to all his sub contractors involved in the order manufacturing.

4.6

A copy of ISO 9001 Certificate shall be included in the offer.

4.7

An approval of documents can never be considered as acceptance of deviations or relaxation to

requirements. A deviation is only possible after specific request to purchaser and purchasers
representative.

4.8

Purchaser/ purchasers representative may verify the control equipment of the manufacturer, its
calibration and the points at which it is located. If during the production certain problem arises,
the purchaser/ purchasers representative may demand supplementary tests.

5.0

MATERIALS

5.1

Material for major components of the valves shall be as indicated in Valve Data Sheet.
In addition, the material shall also meet the requirements specified herein. Other components
shall be as per Manufacturers standard (suitable for service conditions as indicated in valve data
sheet), which shall be subjected to approval by Purchaser / Purchasers representative.

5.2

Carbon steel used for the manufacture of valves shall be fully killed.

5.3

The carbon equivalent (CE) of valve end connections which are subject to further field welding
by Purchaser shall not exceed 0.45% on check analysis for each heat of steel used and shall be
calculated by the following formula:
CE = C + Mn +
6

Cr + Mo + V + Ni + Cu
5
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5.4

The steel used shall be suitable for field welding to pipes, flanges or fittings manufactured under
ASTM 53, A 105, A 106, A 234, A 350, A 352, A 694, A 420, A 333, and
API 5L etc.

5.5

When the ball of valve is manufactured out of C.S, it shall be subjected to 75m (0.003) thick
Electrolysis nickel plating as per ASTM B733 with following classification SC2, type II, class-2.
For Ball made of S.S material, ENP is not mandatory.
The hardness of plating shall be minimum 50 RC.

5.6

For valves specified to be used for Gas service or High Vapor Pressure (HVP) liquid service;
Charpy V-Notch test on each heat of base material shall be conducted as per API 6D, clause 7.5
for all pressure containing parts such as body, end flanges and welding ends as well as bolting
material for pressure containing parts. Unless specified otherwise, the Charpy V-notch test shall
be conducted at 0C. The Charpy V-notch test specimen shall be taken in the direction of
principal grain flow and notched perpendicular to the original surface of plate or forging. The
minimum average absorbed energy per set of three specimens shall be 35 J with an individual
minimum per specimen of 27J. Test procedure shall conform to ASTM A 370 or ISO 148.
For valves specified to be used for other hydrocarbon services, the Charpy V-notch requirements
stated above are not applicable, unless required by the specified material standard as a
mandatory requirement.
When Low Temperature Carbon Steel (LTCS) materials are specified in Valve Data Sheet or
offered by Manufacturer, the Charpy V-notch test requirements of applicable material standard
shall be complied with.

5.7

Valves shall be subjected to hardness test on base material for each heat for pressure containing
parts. A full thickness cross section shall be taken for this purpose and the maximum hardness
shall not exceed 248 HV10 based on minimum four (4) measurements representing the entire
thickness.

6.0

DESIGN AND CONSTRUCTION

6.1

a) Valve design shall be as per API 6D and suitable for the process conditions indicated in the
Data Sheet. The ASME Boiler & Pressure Vessel Code, Section VIII, Division 1 shall be used
to design the valve body. Allowable stress requirements shall comply with the provisions of
ASME B31.3 and B31.8. In addition, corrosion allowance indicated in Valve Data Sheet shall
be considered in valve design. However, the minimum wall thickness shall not be less than the
minimum requirement of ASME B16.34.
b) Corrosion Allowance for all valves to be used in sweet gas services shall be considered nil.
c) The manufacturer shall have valid license to use API monogram on valves manufactured
as per API 6D.

6.2

Fully welded valves shall be used for main line aboveground/underground services. Other
aboveground valves may be of welded or bolted type with 2 piece/3 piece construction. Threaded
body joints shall not be accepted.

6.3

Ball shall be of single piece, solid type construction.

6.4

Valves shall be Full bore or Reduce bore . Full bore valves shall be suitable for the passage
of all types of pipeline scraper and inspection pigs on regular basis without causing damage to

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either the valve component or the pig. The full bore valve shall provide an unobstructed profile for
pigging operations in either direction. Full bore valves shall be designed to minimize
accumulation of debris in the seat ring region to ensure that valve movement is not impeded.
6.5

Reduced bore valves shall be provided if specifically mentioned in data sheet. Valve body shall
be manufactured by casting or forging.

6.6

All valves 4NB and above shall be trunion mounting type. Valves below 4 shall be floating type
unless specifically mentioned in data sheet otherwise.

6.7

Valve seats shall be with primary metal to metal contact. O - Rings or other seals if used for drip
tight sealing shall be encased in a suitable groove in such a manner that it can not be removed
from seat ring and there is no extrusion during opening or closing operation at maximum
differential pressure. The seat rings shall be designed so as to ensure sealing at low as well as
high differential pressures. Seat design with PTFE inserts is not acceptable.

6.8

All valves shall have two seating surfaces which in close position blocks the flow from both
ends. The cavity between the seating surfaces is vented through a bleed connection
provided on the body cavity i.e. the valves shall be Double Block & Bleed (DBB).

6.9

Valves shall be designed to withstand a sustained internal vacuum of at least 1 (one) milli-bar in
both open and closed positions.

6.10

All valves of nominal valve size 200 mm (8) NB & above shall have provision for secondary
sealant injection under full line pressure for seat and stem seals. All sealant injection connections
shall be provided with an internal Non-return valve. Valve design shall have a provision to
replace the sealant injection fitting under full line pressure.

6.11

All valves shall be provided with a vent and drain connection. These connections shall be welded
type as per Fig. 6.11 A/B. Body vent and drain shall be provided with valves (Ball or Plug type).
All these vents & drain connection shall be provided with isolation ball valve as shown in Fig
6.11 A/B. The end connection of vent & drain line to valve body or isolation valves shall be
welded type at underground location and threaded type for above ground location.

6.12

Valve design shall ensure repair of stem seals/packing under full line pressure.

6.13

a) Valve ends shall be either flanged/or butt welded or one end flanged and one end butt welded
as indicated in the Valve Data Sheet. Flanges of the flanged end cast/forged body valves shall
be integrally cast/ forged with the body of the valve. Face to face/end to end dimensions shall
conform to API 6D.
b) The length of butt welding ends shall be sufficient to allow welding and heat treatment without
damage of the internal parts of the valves.
c) Flanged end, if specified shall have dimensions as per ASME B 16.5 for valve sizes up to DN
600 mm (24) excluding DN 550 mm (22) and as per MSS-SP-44/ASME B16.47Series A for
Valve sizes DN 550 mm (22 inches) and for DN 650mm (26) and above. Flange face shall be
either raised face or ring joint type as indicated in Valve Data Sheet. In case of RTJ flanges,
the groove hardness shall be minimum 140 BHN. All flanged face shall have concentric
serration with 125 AARH finish.
d) Butt welding end preparation shall confirm to ASME B 16.25. Incase of difference in thickness
of valve body & mating pipelines, the bevel end of valve shall be as per ASME B 31.8 or
ASME B 31.4 as applicable. The end preparation shall take care of outside diameter of
connecting pipe, wall thickness, material grade, SMYS & Special chemistry of welded material
as indicated in the data sheet.

6.14

The temperature and pressure range of the valves shall be in accordance with the indicated
values on the relevant piping specification and valve data sheet.
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6.15

Wall thickness of parts used for the welding connection with the line pipe shall meet the
following requirements:
a) The maximum allowable stress in the material of butt-weld connection for butt welding shall be
equal to 50% of the minimum yield strength guaranteed by the specification of steel used.

b) The minimum wall thickness for butt welding connection must be greater than or equal to the
largest value of either the calculated minimum thickness of butt welding connections or the
nominal thickness of pipe as indicated on data sheet.
c) If the butt welding connections has a yield strength lower than the yield strength of the pipe to
which it is intended to be welded, the wall thickness in each zone of the butt welding
connection is at least equal to the specified pipe wall thickness times the ratio of minimum
yield strength guaranteed by the specification of the steel of the pipe to minimum yield strength
guaranteed by the specification of the steel of the butt welding connection.
d) The specified pipe wall thickness and grade with which the valve is intended to be used is
specified in the data sheet.
e) All valves under this specification shall be designed to withstand a field hydrostatic test
pressure with non corrosive water. After installation during 24 hours when the ball is partially
or fully open at a pressure level
P = 1.4 X MOP
P = hydrostatic test pressure (bar)
MOP = Maximum operating pressure at 38 C
6.16

Valve shall be provided with ball position indicator and stops of rugged construction at the fully
open and fully closed positions.

6.17

Valves of nominal size, DN 200 mm (8) and larger, shall be equipped with support foot and
lifting lugs. Tapped holes and eyebolts shall not be used for lifting lugs. Height of support foot
shall be kept minimum. The lifting lugs shall be stamped with safe working load.

6.18

In order to avoid stress induced crack and soft seat damage during direct field welding operation
to valve body, all valves shall be supplied with welded pups at both ends which shall be
considered as an integral part of the valves and also the ID of the pup shall match with pipe ID.
The pup piece welding shall be carried out in controlled condition of temperature at
manufacturers workshop. Field welding of pup piece shall not be allowed. Material & length of
pup piece shall be as per Data sheet.

6.19

When indicated in Material Requisition, valves shall have locking devices to lock the valve
either in full open (LO) or full close (LC) positions. Locking devices shall be permanently
attached to the valve operator and shall not interfere with operation of the valve. Locking device
shall be such that the valve shall operate when the differential pressure across the valve
is 3bar.

6.20

Valve design shall be such as to avoid bimetallic corrosion between carbon steel and high alloy
steel components in the assembly. Accordingly, Suitable insulation shall be provided as required.

6.21

The valve stem shall be capable of withstanding the maximum operating torque required to
operate the valve against the maximum differential pressure as per the appropriate class.
The combined stress shall not exceed the maximum allowable stresses specified in ASME
Section VIII, Division 1. The design shall take into account a safety factor of 1.5 based on the
maximum output torque of the operating mechanism. The valve Manufacturer shall guarantee
that the breakaway torque after long periods of non- movement can not exceed the normal

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short term breakaway torque by a factor more than 1.25, and that the safety factor specified
above is not compromised.
6.22

The valve stem shall have anti-blowout feature with antistatic device conforming to BS 5351

6.23

When stem extension requirement is indicated in Valve Data Sheet, the valves shall have the
following provisions:
a) Valves provided with stem extension shall have water proof outer casing. The Length of
stem extension shall be as indicated on the Valve Data Sheet. The length indicated
corresponds to the distance between centerline of the valve opening and the centerline of
the rim of the hand wheel on a vertical shaft or centerline of the hand wheel on a horizontal
shaft.
b) Manual override devices shall be provided on all valves
c)

Vent, drain and sealant connections shall be terminated adjacent to the valve operator by
means of suitable piping anchored to the valve body.

d) The stem extension shall be self relieving.

e) Outer casing of stem extension shall have 3/8 or 1/2 NPT plugs at the top and bottom, for
draining and filling with oil to prevent internal corrosion
6.24

Operating Devices
a) All valves of size > 12NB shall be manually operated & hydraulically actuated. In case of
manual operator, valve sizes, 100 mm (NPS 4) and below shall be wrench/ lever operated.
For Valves from 6 - 12 shall be gear operated.
Valve design shall be such that damage due to malfunctioning of the operator or its control
gear train or power cylinder and other damaged parts can be replaced without the valve cover
being removed.
b) The power actuator shall be in accordance with the Purchaser Specification issued for the
purpose and as indicated in the Valve and Actuator Data Sheet. Operating time shall be as
indicated in Valve Data Sheet. Valve operating time shall correspond to full close to full open
/full open to full close under maximum differential pressure corresponding to the valve rating.
For actuated valves, the actuators rated torque output shall be 1.25 times the break torque
required to operate the ball valve under the maximum differential pressure corresponding to
the Valve Class Rating.
c) For the manual operator of all valves, the diameter of the hand wheel or the length of
operating wrench shall be such that under the maximum differential pressure, the total force
required to operate the valve does not exceed 350N. Manufacturer shall also indicate the
number of turns of hand wheel (In case of gear operators) required for operating the valve
from full open to full close position. The wrench length or hand wheel diameter shall be in
accordance with API 6D requirements. The manufacturer shall indicate the number of turns
of the hand wheel (for gear operators), required for operating the valve from fully open to the
fully closed position.
d) Direction of operation of hand wheel or wrench shall be in clock-wise direction while closing
the valve. Hand wheels shall not have protruding spokes.
e) Gear operators, when provided, shall have a self-locking provision and shall be fully encased
in water proof/splash proof enclosure and shall be filled with suitable grease.

6.25

Welding including repair welding of pressure retaining parts shall be as per welding
procedure qualification specified in ASME Section IX. The procedure qualification shall also
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Include impact test and hardness test when required as per Clause 5.6, 5.7, 7.5 and 7.6 of this
specification and shall meet the requirements as specified therein.
6.26

The welders involved in welding shall be qualified in accordance with ASME Section IX.

6.27

Repair by welding is not permitted for forged body valves. However repair by welding as per
ASME B 16.34 is permitted for cast body valves. Repair shall be carried out before any heat
treatment of casting is done. Repair welding procedure qualification shall also include impact test
and hardness test when required as per Clause 5.6, 5.7, 7.5 and 7.6 of this specification and
shall meet the requirements as specified therein.

6.28

The tolerance on internal diameter and out of roundness at the ends for welded ends valves
shall be as per connected pipe specification as indicated in the Valve Data Sheet.

6.29

When specified on the Valve Datasheet, Ball Valves shall be fire safe in accordance with
API 6FA, for which qualifying certificates, covering the range of items offered, shall be supplied
by the Manufacturer.

7.0

INSPECTION AND TESTS

The Manufacturer shall perform all inspection and tests as per the requirements of this
specification and the relevant codes, prior to shipment, at his Works. Such inspection and tests
shall be, but not limited to, the following:

7.1

7.2

The valve manufacturer must deliver a Certificate EN 10204 3.2 stating the quality, the
mechanical properties (yield strength, tensile strength, and impact test at 0 C for high tem,-20
C for low tem), the chemical analysis the process of manufacture and the marking (for ex: - heat
number of material) A new chemical analysis (upgradation) shall be done on specimen of valve in
presence of TPIA.
All valves shall be visually inspected. The external and internal surfaces of the valves shall be
free from any arc strikes, gouges and other detrimental defects.

7.3

Dimensional check on all valves shall be carried out as per the Purchasers approved drawings.

7.4

Chemical composition and mechanical properties shall be checked as per relevant material
standards and this specification, for each heat of steel used.

7.5

Pressure containing parts of all valves such as body, bonnet, flange, welding ends and balls etc
shall be subjected to impact test on each heat of base material as per API 6D CL.7.5.

7.6

Notch toughness properties Charpy V: The standard impact test temperature is 0 C for high
tem,-20 C for low tem. The average value per series of 3 test specimen shall be equal to 35
J/cm. The minimum value per test specimen shall be equal to 35 J/cm; this value may drop to
28 J/cm per test specimen per series.

7.7

Non Destructive Examination

a) Non-destructive examination of individual valve material and component consisting of but not
limited to castings, forgings, plates and assembly welds shall be carried out by the
Manufacturer. All castings shall be wet magnetic particle inspected 100% of the internal
surfaces. Method and acceptance shall comply with MSS-SP-53.
b) Body castings of all valves shall be radio graphically examined as per ASME B16.34.
Procedure and acceptance criteria shall be as per ASME B 16.34. For all sizes, body casting
shall be subjected to 100% radiography.
c) All forgings shall be ultrasonically examined in accordance with the procedure and acceptance
standard of Annexure E of ASME B 16.34. All forgings shall be subjected to wet magnetic

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particle inspection on 100% of the internal surfaces. Method and acceptance shall comply with
MSS-SP-53.

d) Bodies and bonnets made by welded assembly of segments of castings, forgings,

combinations thereof shall be examined, as applicable, by methods of 7.7 (b) for cast
components or 7.7 (c) for forged components and plates.
7.8

Full inspection by radiography shall be carried out on all welds of pressure containing parts.
Acceptance criteria shall be as per ASME B 31.3 or ASME B31.8 as applicable and API 1104.

7.9
a) All finished weld ends subject to welding in field shall be 100% ultrasonically tested for
lamination type defects for a distance of 50 mm from the end. Laminations shall not be
acceptable.
b) Weld ends of all cast valves subject to welding in field shall be 100% radio graphically
examined and acceptance criteria shall be as per ASME B16.34.
c) After final machining, all bevel surfaces shall be inspected by dye penetrate or wet magnetic particle methods. All defects longer than 6.35 mm shall be rejected. Rejectable
defects must be removed. Weld repair of bevel surface is not permitted.
7.10

All valves shall be tested in compliance with the requirements of API 6D. During pressure
testing, valves shall not have sealant lines and other cavities filled with sealant, grease or
other foreign material. The drain, vent and sealant lines shall be either included in the
hydrostatic shell test or tested independently. No leakage is permissible during hydrostatic
testing. The body cavity self-relieving feature meeting the requirements of clause 6.8 of this
specification shall also be checked.

7.11

A supplementary air seat test as per API 6D, Appendix C, Para C3.3 Type II shall be carried
out for all valves. A bubble tight seal is required without the use of any sealant. No leakage is
allowed. Test pressure shall be held for at least 15 minutes.

7.12

Valves shall be subjected to Operational Torque Test as per Appendix C, Para C.6, API 6D
under hydraulic pressure equal to maximum differential pressure corresponding to the valve
rating. For manually operated valves, it shall be established that the force required to operate
the valve does not exceed the requirements stated in section 6.24 (c) of this specification.

7.13

Power actuated valves shall be tested after assembly of the valve and actuator, at the valve
Manufacturers works. At least five Open-Close-Open cycles without internal pressure and
five Open-Close-Open cycles with maximum differential pressure corresponding to the valve
rating shall be performed on the valve actuator assembly. The time for Full Open to Full
Close shall be recorded during testing. If required, the actuator shall be adjusted to ensure
that the opening and closing time is with in the limits stated in Valve Data Sheet. The Hand
operator provided on the actuator shall also be checked after the cyclic testing, for
satisfactory manual over-ride performance.
These tests shall be conducted on minimum one valve out of a lot of five (5) valves of the
same size, rating and the actuator model/type. In case, the tests do not meet the
requirements, retesting/rejection of the lot shall be decided by the Purchasers Inspector.

7.14

Subsequent to successful testing as specified in clause 7.10, 7.11, 7.12 and 7.13 above,
one(1) valve out of the total ordered quantity shall be randomly selected by the Company
Representative for cyclic testing as mentioned below:
a) The valve shall be subjected to at least 5 Open-Close-Open cycles with maximum
differential pressure corresponding to the valve rating.
b) Subsequent to the above, the valve shall be subjected to hydrostatic test and
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supplementary air seat test in accordance with clause 7.10 and 7.11.

In case this valve fails to pass these tests, the valve shall be rejected and two more valves
shall be selected randomly and subjected to testing as indicated above. If both valves pass
these tests, all valves manufactured for the order (except the valve that failed) shall be
deemed acceptable. If either of the two valves fails to pass these tests, all valves shall be
rejected or each valve shall be tested at the option of manufacturer.
Previously carried out prototype test of similar nature shall not be considered acceptable in
place of this test.
7.15

Purchaser reserves the right to perform stage wise inspection and witness tests as indicated
in clauses 7.1 to 7.14 above at Manufacturers works prior to shipment. Manufacturer shall
give reasonable access and facilities required for inspection to the Purchaser. Purchaser or
Purchasers representative reserves the right to require additional testing at any time to
confirm or further investigate a suspected fault. The cost incurred shall be borne to
Manufacturer.
In no case shall any action of Purchaser or his inspector shall relieve the Manufacturer of his
responsibility for material, design, quality or operation of valves .
Inspection and tests performed/witnessed by the Purchasers Inspector shall in no way
relieve the Manufacturers obligation to perform the required inspection and tests.

8.0

TEST CERTIFICATES
Manufacturer shall submit the following certificates:
a) Mill test certificates relevant to the chemical analysis and mechanical properties of the
materials used for the valve construction as per the relevant standards.
b) Test certificates of hydrostatic and pneumatic tests complete with records of timing and
pressure of each test.
c) Test reports of radiograph and ultrasonic inspection.
d) Test report on operation of valves conforming to clause 7.12, 7.13 and 7.14 of this
specification.
e) All other test reports and certificates as required by API 6D, this specification and data sheets.
The certificates shall be valid only when signed by Purchasers Inspector. Only those valves
which have been certified by Purchasers Inspector shall be dispatched from Manufacturers
works.

9.0

PAINTING, MARKING AND SHIPMENT

9.1

Valve surface shall be thoroughly cleaned, freed from rust and grease and applied with
sufficient
coats of corrosion resistant paint. Surface preparation shall be carried out by
shot
blasting to SP- 6 in accordance with Steel Structures Painting Council - Visual
Standard
SSPC-VIS-1. For the valves to be installed underground, when indicated
in Valve Data Sheet,
the external surfaces of buried portion of the valve shall be
painted with three coats of suitable
coal tar epoxy resin
with a minimum dry film
thickness of 300 microns.

9.2

All valves shall be marked as per API 6D. The units of marking shall be metric except
nominal diameter, which shall be in inches.

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9.3

Valve ends shall be suitably protected to avoid any damage during transit. All threaded and
machined surfaces subject to corrosion shall be well protected by a coat of grease or other
suitable material. All valves shall be provided with suitable protectors for flange faces,
securely attached to the valves. Bevel ends shall be protected with metallic or high impact
plastic bevel protectors.

9.4

All sealant lines and other cavities of the valve shall be filled with sealant before shipment.

9.5

Packaging and shipping instructions shall be as per API 6D and procurement documentation.
All valves shall be transported with ball in the fully open condition.

9.6

On packages, following shall be marked legibly with suitable marking ink:

a) Order Number
b) Manufacturers Name
c) Valve size and rating
d) Tag Number
e) Serial Number

10.0

SPARES AND ACCESSORIES

10.1

Manufacturer shall furnish list of recommended spares and accessories for valves required
during start-up and commissioning.

10.2

Manufacturer shall furnish list of recommended spares and accessories required for two years
of normal operation and maintenance of valves.

10.3

Manufacturer shall quote for spares and accessories as per Material Requisition.

11.0

DOCUMENTATION

11.1

At the time of bidding, Manufacturer shall submit the following documents:

a)

Filled in Data Sheet

b)

General arrangement/assembly drawings showing all features and relative positions and
sizes of vents, drains, gear operator/ actuator, painting, coating and other external parts
together with overall dimension.

c)

Sectional drawing showing major parts with reference numbers and material
specification. In particular a blow up drawing of ball-seat assembly shall be furnished
complying with the requirement of Clause 6.7 of this specification.

d)

Reference list of similar ball valves manufactured and supplied in last five years
indicating all relevant details including project, year, client, location, size, rating, service
etc.

e)

Torque curves for the power actuated valves along with the break torque and maximum
allowable stem torque. In addition, sizing criteria and torque calculations shall also be
submitted for power actuated valves.

f)

Clause wise list of deviations from this specification, if any.

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11.2

g)

Descriptive technical catalogues of the manufacturer.

h)

Installation, Operational and Maintenance Manual.

i)

Copy of valid API 6D Certificate.

j)

Details of support foot including dimensions and distance from valve centerline to bottom
of support foot.

Within three weeks of placement of order, the Manufacturer shall submit four copies of, but not
limited to, the following drawings, documents and specifications for Purchasers approval:
a)

Detailed sectional drawings showing all parts with reference numbers and material
specifications.

b)

Assembly drawings with overall dimensions and features. Drawing shall also indicate
the number of turns of hand wheel (in case of gear operators) required for operating the
valve from full open to full close position and the painting scheme. Complete dimensional
details of support foot (where applicable) shall be indicated in these drawings.

c)

Welding, heat treatment and testing procedures (Quality Assurance Plan).

d)

Details of corrosion resistant paint to be applied on the valves.

Manufacturing of valves shall commence only after approval of the above documents. Once the
approval has been given by Purchaser, any changes in design, material and method of
manufacture shall be notified to Purchaser whose approval in writing of all changes shall be
obtained before the valve is manufactured.
11.3

Prior to shipment, Manufacturer shall submit to Purchaser one reproducible and six copies of the
following:
a) Test certificates as per clause 8.0 of this specification.
b) Manual for installation, erection, maintenance and operation instructions including a list of
recommended spares for the valves.

11.4

CD containing all docs in 11.2 & 11.3 shall be submitted within 30 days from the approval date,
Manufacturer shall submit to Purchaser one reproducible and six copies of the approved
drawings, documents and specifications as listed in clause 11.2 above.

11.5

All documents shall be in English language only.

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FIG - 6.11 A

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FIG - 6.11 B

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