STANDARDS PUBLICAT'IION

KOC STANDARD FOR

PLUG VALVES

DOC NO : KOC-MP-016
(FORMERL Y KOC 38 7/2 1/21

I STANDARDS DIVISION
DOC NO. KOC-MP-016 I Pane 1 of T7 I REV. 1

KUWAIT OIL COMPANY (K.S.C.)

KOC STANDARD
FOR
PLUG VALVES

DOC NO: KOC-MP-016

I FORMERL Y KOC 387/2 1/2 1

ISSUlNG AUTHORITY :

STANDARDS DlVlSlON
DOC NO. KOC-MP-016 I Pane 2 of 1 7 I REV. 1

KOCSTANDARDFOR

PLUG VALVES

DOC NO : KOC-MP-016
( FORMER1 Y KOC 387/27/2 )
 TABLE OF CONTENTS

PAGE NO.

1.0 SCOPE 4

2.0 GENERAL I APPLICATION 4

3.0 TERMINOLOGY 4

4.0 REFERENCE CODES AND STANDARDS 5

5.0 ENVIRONMENTAL CONDITION 6

6.0 MATERIAL 6

7.0 DESIGN REQUIREMENT 10

8.0 OPERATION 12

9.0 INSPECTION AND TESTING 12

10.0 QUALITY ASSURANCE 14

11.0 MARKING 14

12.0 DOCUMENTATION 15

13.0 SHIPMENT 15

14.0 PLUG VALVE DATA SHEET I ORDERlNG lNFORMATlON 16

DOC NO. KOC-MP-016 I Pane 4 of 1 7 1 REV. 1

1.0 SCOPE

1.1 This Standard covers the minimum requirement for design, manufacture and supply
of Steel Balanced Taper Plug Valves for sizes and ratings as listed below and for
all services (process & utilities) required for KOC's applications.

15-40mm(l/zn-1%") ANSI150 t o 2500 BS 5353

-
50 900 mm (2"-36") ANSI 150 t o 2500 API Spec 6D IAPI Std 599
79.4 mm (3 118") API 2000, 5000 API Spec 6A

1.2 Valves with pressure rating 2 API 10000 are not in the scope of this Standard.

2.1 Plug Valves shall be used for the following applications:

Tight shut-off isolation on oil & gas services when reliability and speed of
operation are prime considerations.
Abrasive & sand entrained services on applications like flowlines, manifolds
& headers.
b By-pass & blowdown applications on gas service (can be operated against
full differential pressure & limited throttling applications)
w Kicker valves t o scraper trap assembly
b Onloff high differential pressure application for water and gas injection
facilities

2.2 Plug Valves shall not be used for pigging applications.

3.0 TERMINOLOGY

KOC Kuwait Oil Company (K.S.C.)

ENP Electroless Nickel Plating
NDE- Non-Destructive Examination
Plug Valves : Steel Balanced Taper Plug Valves
PSL Product Specification Level (As per API Spec 6A)
PR1 Performance Requirement Level One (As per API Spec 6A)
PT Liquid Penetrant Examination
RF Raised Face
RTJ Ring Type Joint
DOC NO. KOC-MP-016 I Page 5 of 1 7 I REV. 1

REFERENCE CODES AND STANDARDS

Plug Valves shall be manufactured and supplied in accordance with the latest
edition of codes, with additions and modifications as indicated in this Standard.
Nothing in this Standard shall be construed as waiving any mandatory requirement
of the referenced codes.

In the event of conflict between this Standard and the codes referenced herein, the
most stringent requirement shall apply, unless otherwise specified. Any exceptions
or deviations from this Standard, along with their merits & justification, shall be
brought to the attention of KOC's Controlling Department for their review,
consideration and amendment by Standards Division (if required).

List of applicable codes and standards:

API Spec 6A Specification for wellhead & christmas tree equipment.

API Spec 6D Specification for pipeline valves
API Spec 6FA Specification for fire test for valves
API Std 599 Metal Plug Valves flanged & welding ends
API Std 605 Large diameter carbon steel flanges
API Spec 01 Specification for quality programs

ASME B 16.5 Steel pipe flanges and flanged fittings

ASME B 16.10 Face-to-face and end-to-end dimensions of valves
ASME B 16.34 Valves-flanged, threaded and welding ends
ASME B 16.47 Large diameter steel flanges
ASTM Testing & Material specifications
(as referred in the text)

BS 970 Specification for wrought steels

BS 1560 Circular flanges for pipes, valves and fittings
BS 2080 Specification for face-to-face, centre-to-face, end-to-end
and centre-to-end dimension of valves
BS 5353 Steel Plug Valves
BS 6755 Pt.1 Specification for production pressure testing
requirements
BS 6755 Pt.2 Specification for fire type-testing requirements

Steel pipeline flanges

Standard marking system for valves, fittings, flanges &
unions

NACE MR0175 Sulfide stress cracking resistant metallic materials for oil
field equipment
KOC Standards

KOC-G-004 KOC Standard for packing, marking and documentation

KOC-G-007 KOC Standard for basic design data
DOC NO. KOC-MP-016 I Page 6 of 17 1 REV. 1

ENVIRONMENTAL CONDITION

The environment of Kuwait, is severe on all equipment and must be considered

carefully before procurement of plant and equipment. It must be assumed that,
unless otherwise specified, equipment may be subject t o sand and fine particle
dust storms, sand laden winds, chemical contaminants and extreme temperatures.

KOC Standard for Basic Design Data, KOC-G-007, provides the detailed design
information regarding the environmental, site and utility supply conditions
prevailing throughout the KOC facilities.

MATERIAL

Material specification of the main parts of Plug Valves shall be as per clauses 6.5,
6.6, 6.7 or 6.8 of this Standard.

Use of asbestos in any form is prohibited.

For sour service, NACE standard MR0175 shall apply t o all wetted components.
Appropriate product specification level shall be used for API Spec 6A Plug Valves
with NACE MR0175 application.

Carbon content of all pressure-containing parts for carbon steel involved in welding
operations shall be restricted as follows:

(i) Carbon = 0.25% maximum

(ii) Carbon equivalent = C +Mn/6 S 0.41 %

Where C = Carbon, Mn = Manganese

For alloy steel and stainless steel, carbon content shall be limited to ensure
weldability .

Electroless Nickel Plating (ENP):

(i) Standard: ENP shall be as per ASTM B 733, SC4, Type II & Ill and Class 1
or 2 or 3 (as per manufacturer's standard).
(ii) Composition: 10-12 % Phosphorus, maximum 0.05% unspecified metals and
remainder as Nickel.
(iii) Thickness 0.003" (76 ym),unless otherwise specified.
(iv) Test Required: Appearance, thickness, adhesion, porosity (Ferroxyl Test),
hardness alloy composition and corrosion.
DOC NO. KOC-MP-016 1 Pane 7 of 1 7 1 REV. 1

SERVICE Sour hydrocarbon gaslliquid

NACE MR0175 -
Yes
SIZE, ENDS AND RATING To be specified in Data Sheet

Body I Carbon Steel

ForgedlCast
ASTM A105, or, A216 WCBIWCC

Cover Carbon Steel ASTM A 10 5 or, A216 WCBIWCC,

ForgedlCastIRolled or, ASTM A516 61.70,
or, BS970 GR070M20 ,
or, BS970 GR 709 M 40

Plug Carbon Steel [ A 1051A216 WCBIWCCII +ENP

ForgedlCastlbar + & Anti-friction impregnated, or,
overlay [ A216 WCC +Ni. Boron1
Hastelloy overlay 0.003", or,
1714 PH S.S I
+ Anti-friction impregnated

Stem [ A105, or, 17-4PH , or, K-Monel,

or, AlSl 4140, or,
BS 970 GR080M40 I
+ Anti-friction impregnated
Firesafe Graphite IGraphite filament

Stem seal Emergency Manufacturer's standard

packing injectable (non-asbestos)
on stream

Body studlnuts
SERVICE Treated Sea water for high pressure
injection; High pressure Gas injection
NACE MR0175 -
No
SIZE, ENDS AND RATING To be specified in Data Sheet

Carbon Steel ASTM A105, or, A216 WCBlWCC

ForgedICast

Cover Carbon Steel ASTM A105 or, A21 6 WCBIWCC,

ForgedlCastlRolled or, ASTM A516 Gr.70,
or, BS970 GR070M20 ,
or, BS970 GR 709 M 40

Carbon Steel [ A 105lA216 WCBMICCI] + ENP

Plug ForgedlCastlbar + & Anti-friction impregnated, or,
overlay [ A216 WCC + Ni. Boron1
Hastelloy overlay 0.003", or,
1714 PH S.S 1
+ Anti-friction impregnated

Stem [ A105, or, 17-4PH , or, K-Monel,

or, AlSl 4140, or,
BS 970 GR080M40 1
+ Anti-friction impregnated

Firesafe Graphite 1 Graphite filament

Stem seal Emergency Manufacturer's Standard

packing injectable (non-asbestos)
on stream

Body studlnuts ---

 gaslliquid
NACE MR0175 -
No
SIZE, ENDS AND RATING To be specified in Data Sheet

Body Carbon Steel ASTM A 105, or, A 216 WCBI WCC,

- --
ForgedlCast

Carbon Steel ASTM A105, or, A216 WCBIWCC or,

Cover ForgedICastlRolled ASTM A516 Gr.70, or, BS970 GR
070M20, or, BS 970 GR 709M40

Carbon Steel I ASTM A 105/216WCBlWCCI BS970

Plug Forgedlcast + case GR070M20 1 + case hardened +
hardened Anti-friction impregnated

Stem I A 105, or, AlSl 4140, or,

17-4 PH, or, BS970 GR080M40 I
+ Anti-friction impregnated

Firesafe Graphite I Graphite filament

Stem seal
Emergency packing Manufacturer's standard
injectable on stream (non-asbestos)

Body studlnuts
6.8 SERVICE Glycol, chemicals inhibitors, corrosive
water and other corrosive media.
NACE MR0175 -
No
SIZE, ENDS AND RATING To be specified in Data Sheet
r

Main Parts
Bodylcover Stainless steel ASTM A 182 Gr.F316 (S31600),
ForgedICastlRolled or, A351 Gr. CF8MlAISI 316

Plug Stainless Steel [ A182 Gr.F316(S31600), or,

ForgedlCast AIS1316, or, A351Gr.CF8M 1 +
001"ENP + Anti-friction
impregnation

Stem [ A 812 Gr.F316, or, 17-4 PH

S.S, or, AIS1316 I + 003"ENP
+ Anti-friction impregnation, or,
[ K Monel only ]
Stem seal Firesafe Graphite 1 Graphite filament
Emergency packing Manufacturer's standard
injectable on stream (non-asbestos)
Body studlnuts K Monel, or, Monel400, or,
A193 Gr.B8M 1 A 194 Gr.8M

For abrasive services with high sand content or high velocities or both, the
materials in clauses 6.5,6.6,6.7, and 6.8 shall be modified so that plug taper seat
& body taper seat shall have an overlay of stellite having finished thickness of 1.6
mm minimum. The stellite deposit will overlap at least 25 mm from the edge of the
plug & body port into the plug portlbody passage.

DESIGN REQUIREMENT

Valve pattern shall be regular, short or venturi as specified in the Data Sheet.

Valves will be of pressure balanced inverted taper design, having an inherent

feature using the line pressure t o ensure that the line pressure can not cause taper
locking of the plug in the taper. However, in class 150, standard type, taper Plug
Valves having feature of spring balance shall also be acceptable.
DOC NO. KOC-MP-016 I Page 11 of 1 7 I REV. 1

7.3 End connections shall be as follows:

Data Sheet shall specify end connection based on the relevant piping specification
and generally as per the following guideline:

< 2" NB I all I SW or THRD, 8 16.1 1 (3000#) 1

r 2" NB 150,300 & 600 Flanged, RF, B16.5
r 2" NB 900,1500 & 2500 Flanged, RTJ, B16.5
and API 2000, 5000
11 Note: RF flanges shall be serrated face M s h as per ANSI B 76.5. 11

Soft seats to achieve a seal between the body & the plug shall not be permitted.

Valves shall have provision of seat sealant injection under full line pressure.

Valves shall have provision of emergency stem packing injection under full line
pressure.

All valves shall be provided with an jndicator to show the position of the plug port.
Wrench shall not be used as an indicator. Stops shall be provided of rugged
construction for both the fully open and fully closed position of the valve.

Open : in line of flow

Close : perpendicular t o the flow

Valves of size > 6" NB shall be equipped with lifting lugs.

The stem configuration shall ensure that blow- can not occur
inadvertently.

Shell watl thickness shall be as per Tables 1A and 1B of API Std 599.

Plug Valves shall be Fire-Tested-Desigll as per API Spec 6FA or BS 6755 Part 2.

Face t o face & end to end dimensions shall conform t o API Spec 6D for size
2 2" NB ,and to BS 2080 for sizes upto 1.5" NB.

7.13 API 2000 & API 5000 valves will conform to API 6A having Product Specification
-
Level (PSL 2) & Performance Requirement Level One (PR I ) , unless otherwise -
specified in Data Sheet.
OPERATION

Valve operation shall be as follows:

b

ANSI Class Shes Operation

1 5 0 and 300 1 5 6" NB 1 leverlwrench
> 6" NB gear operated
600 and 900 s 4" NB leverlwrench -

> 4" NB gear operated

1500 and 2500 S 3" NB leverlwrench

&- -

API 2000, 5000 I > 3" NB I gear operated

The length of the wrench or diameter of the handwheel for direct or gear operated
valves shall (after opening and closing a new valve at least three times) be such
that a force not exceeding 350 Newton (N) shall be required to operate from either
the open or closed position under the maximum differential pressure recommended
by the manufacturer.

Actuators if required shall be specified in Data Sheet.

Handwheelllever shall be supplied along with each valve and shall be marked t o
indicate the direction of opening and closing and .
INSPECTION AND TESTING

Material test certificates for all pressure containina components (ie.body and cover)
of the valve shall be furnished by the manufacturer. For other components like
plug, stem, nuts & bolts material compliance certificates shall be issued by
manufacturer. Where valves are required for sour service material certificates for
body & cover shall include hardness limitations as per NACE MR0175.

Hvdro-tic/Pneurnatic Tests:

Steel Plug Valves (BS 5353 or API Spec 6D) shall be subjected to hydrostatic shell
and seat tests and pneumatic tests as per BS 6755 Part 1, or, Section 5 of API
6D. Pneumatic seat Test shall be mandatory. There shall be no leakage under test
pressure. Certificates shall be furnished by the manufacturer.
DOC NO. KOC-MP-016 I Page 13 of 1 7 REV. 1

Third Dartv ins~ectionif required shall be specified in the Data Sheet. Following
shall be the scope of third party inspection (as applicable) but not necessary be
limited t o :

Witness all tests and perform visual inspections deemed essential to verify
the conformity to this Standard.
Witness surface contact test. The plug shall be dressed with engineers blue
and placed into the body so that the weight of the plug sits against the
taper. If necessary, the cover or base plate may be placed in position. The
valve shall then be operated from fully open t o fully closed 3 times. The
plug and body bore will then be examined for surface contact which shall
be at least 90% of total area. The non-contacted area must be distributed
in such a way so as not to propagate leaks.
This (witnessing) may be waived if plug and body are lapped together and
subsequently vacuum tested in dry condition for perfect mate.
Witness demonstration by manufacturer to show that the plug is balanced
and it does not lock into the body.
Review laboratory material physical and chemical test certificates of
pressure containing components as per clause 9.1.
Check marking as per the applicable standard including the service
identification & monogram.
Visual inspection and dimensional check on assembled valves.
Witness performance test for actuators on assembled valves.
Witness ENP test for appearance, thickness, adhesion, porosity, hardness
and corrosion on test coupons.
Check radiographic films, as applicable.
Review fire safe test report (type test) as per clause 9.4.
Witness hydrostatic and pneumatic tests.
Sign and stamp all test resultslcertificates.
Witness packing of valves as per clause 13. Boxlcrate shall be stamped or
stencilled to indicate that packing has been inspected, and the contents tally
with the packing list. This is not required in the event of containers being
used in lieu of cases.

For Steel Plug Valves valid fire-safe test re~ort,giving details of the fire type-test
shall be provided both along with quotation and order.

For valves t o API Spec 6A, manufacture shall provide proof of valid API Spec 6A
Monogram along with the quotation. Third party inspector shall ensure material
traceability by identifying heat marks with serial numbers and that the material
comply with PSL-2 & PR-1, temperature rating, material grades etc, stated in this
Standard and Data Sheet. The manufacturer's quality assurance shall be verified
to comply with the requirements of API Spec 6A.

For valves t o API Spec 6D, manufacture shall provide proof of valid API Spec 6D
Monogram along with the quotation. The manufacturer's quality assurance shall
be verified to comply with the requirements of API Spec 01.
DOC NO. KOC-MP-016 Page 14 of 17 REV. 1

9.6 NDE of Plua Valves

9.6.1 Ring Joint Grooves:

All ring joint grooves shall be examined by PT (Liquid Penetrant Examination) to

ASTM E165.

Acceptance criteria:
b no indications in the ring contact area of groove walls
b no linear indications allowed for sour service valves
b no linear indications in excess of 2 mm allowed for valves for
non-sour service
b no rounded indications in excess of 2 mm
b no rounded indication clusters in excess of 10 mm2

9.6.2 Valve Body:

The manufacturer's quality assurance programme will have for 8" class 1500# &
above radiographic examination of sample castings as per Annex B of ASME B
16.34. Additional radiography requirement, i f any shall be specified in Data Sheet.

9.6.3 For stellited surfaces the crack detection shall be done by dye penetrant test &
acceptance criteria shall be no indications in the seating area.

10.0 QUALITY ASSURANCE

The manufacturer shall operate a quality system which ensures that the
requirements of this Standard are achieved. The quality system shall preferably be
based on IS0 9000 series of standards and manufacturer shall demonstrate
compliance by providing a copy of the accredited certificate or the manufacturer's
quality manual. Verification of the Vendor's quality system is normally part of the
pre-qualification procedure, and is therefore not detailed in the core text of this
specification.

11.0 MARKING:

Marking shall be as per API Spec 6D or BS 5353 and KOC Standard for Packing,
Marking and Documentation (KOC-G-004). Name plate used shall be stainless
steel. Service identification shall be clearly marked in the name or additional plate
as per clauses 6.516.616.716.8 (ie. SOUR HYDROCARBON GASlLlQUlD etc.)
 DOC NO. KOC-MP-016 I Page 1 5 of 1 7 I REV. 1

All correspondences, drawings, instructions, data sheets, design calculations, or

any other written information shall be in English language. All dimensions, units
of measurement, physical constants, etc. shall be in SI units, unless otherwise
specified.

Refer KOC Standard for packing, marking and documentation, KOC-G-004, for
further details.

13.0 SHIPMENT

13.1 Painting and corrosion prevention shall be as per API Spec 6D.

13.2 The threaded ends (if applicable) shall be protected with plastic plugs. End flanges
shall be fully blanked t o protect the gasket surfaces and valve internals with woodl
metal Iplastic. The protective cover shall be securely attached to the valve ends
by suitable devices. Valves shall be packed with the plug in open position. Stems
shall be effectively sealed against the ingress of dirt and moisture.

13.3 Valves shall be packed individually or collectively in wooden boxes or crates in a

manner that will prevent shifting within the package.

13.4 A copy of packing list shall be included in each boxlcrate. Each valve shall be
clearly identified in the packing list with proper marking.

13.5 One copy of test certificates as per clauses 9.1 and 9.2 shall be furnished also
along with the valves.

L
14.0 PLUG VALVE DATA SHEETIORDERING INFORMATION

Valve nominal size: mm(inch) ANSI Class:

Steel Plug Valve as per: 0 BS 5353 0 API Std 599 API Spec 6D 0 API Spec 6A

Ends: SW BW 0 THRD FLGD ( Flange 0 RF RTJ )

Flanges: 0 816.5 API 605 B 16.47 0 BS 1560 0 MSS-SP-44

NACE MR0175: 0 yes no

Service: KOC-MP-016 Clause 6.5 0 6.6 0 6.7 6.8

Clause 6.9 is applicable: no 0 yes

Design temperature (max): OC (OF) Design pressure (max): kPa1psig

Design temperature (min): OC (OF) Design pressure (min): kPalpsig

Valve body pattern: regular short venturi 0 any

Flow medium composition:

Product SpecificationlPerformance Requirement Level for API Spec 6A valves

Locking device required: 0 no 0 yes

Stem extension required: 0 no 0 yes

(If yes) specify length from centre line of body to centerline of handwheelltop of wrench
mm

Additional Radiography: 0 no 0 yes

(If yes) Specify

Special documentation: 01 no 01 yes

(If yes) Specify

Third Party Inspection: [II no 0 yes

Normal painting and corrosion prevention as per API 6D: yes 0 no

Specid painting, protection and packing requirement: O no [II yes

(If yes) Specify

Actuator: [II no [II yes

(If yes) Specify
DOC NO. KOC-MP-016 I Page 1 7 of 17 I REV. 1

14.0 PLUG VALVE DATA SHEET 1 ORDERING INFORMATION (CONTD ) ...

ADDITIONAL WFORMATlON FOR FIEPLACEMENT VALVES

Manufacturer's name & model no.

Original purchase order no.

Tag No. 1 Serial No. (if any)

Part No. and description (for ordering of parts)

Applicable drawing reference

Relevant dimensions

Pressureltemperature ratings