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PMRC Mar Va 122 PDF
PMRC Mar Va 122 PDF
PMRC TECHNICAL SPECIFICATION
VALVES – GENERAL REQUIREMENTS
PMRC MAR VA/122
March 2014
© 2014 PETROLIAM NASIONAL BERHAD (PETRONAS)
All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form
or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright
owner. PETRONAS Technical Standards are Company’s internal standards and meant for authorized users only.
PMRC MAR VA/122
VALVES – GENERAL REQUIREMENTS March 2014
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FOREWORD
PETRONAS Technical Standards (PTS) has been developed based on the accumulated knowledge,
experience and best practices of the PETRONAS group supplemented by national and international
standards where appropriate. The key objective of PTS is to ensure standard technical practice
across the PETRONAS group.
Compliance to PTS is compulsory for PETRONAS‐operated facilities and Joint Ventures (JVs) where
PETRONAS has more than fifty percent (50%) shareholding and/or operational control, and includes
all phases of work activities.
Contractors/manufacturers/suppliers who use PTS are solely responsible in ensuring the quality of
work, goods and services meet the required design and engineering standards. In the case where
specific requirements are not covered in the PTS, it is the responsibility of the
Contractors/manufacturers/suppliers to propose other proven or internationally established
standards or practices of the same level of quality and integrity as reflected in the PTS.
In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or
completeness of the information contained in PTS. The Contractors/manufacturers/suppliers shall
ensure accuracy and completeness of the PTS used for the intended design and engineering
requirement and shall inform the Owner for any conflicting requirement with other international
codes and technical standards before start of any work.
PETRONAS is the sole copyright holder of PTS. No part of this document may be reproduced, stored
in a retrieval system or transmitted in any form or by any means (electronic, mechanical, recording
or otherwise) or be disclosed by users to any company or person whomsoever, without the prior
written consent of PETRONAS.
The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be
kept in safe custody and shall ensure its secrecy is maintained and provide satisfactory information
to PETRONAS that this requirement is met.
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Table of Contents
1.0 INTRODUCTION ................................................................................................... 4
2.0 SUMMARY OF CHANGES ..................................................................................... 4
3.0 MATERIAL REQUIREMENTS ................................................................................. 4
3.1 CHEMICAL COMPOSITION ......................................................................................... 4
3.2 HEAT TREATMENT ..................................................................................................... 6
3.3 IMPACT TESTING ....................................................................................................... 7
3.4 CORROSION TESTING .............................................................................................. 10
3.5 MICROSTRUCTURE DETERMINATION...................................................................... 11
4.0 WELDING AND HARD FACING REQUIREMENTS .................................................. 12
5.0 VALVES MANUFACTURED FROM BAR MATERIAL............................................... 14
6.0 LIFTING POINTS ................................................................................................. 14
7.0 PUP PIECES ........................................................................................................ 14
8.0 NON‐DESTRUCTIVE EXAMINATION .................................................................... 14
8.1 INSPECTION SCOPE .................................................................................................. 14
8.2 EXECUTION .............................................................................................................. 15
8.3 DEFECT REMOVAL AND WELD REPAIR .................................................................... 18
9.0 DOCUMENTATION ............................................................................................. 21
10. CERTIFICATION .................................................................................................. 21
11. WITNESSING BY THE OWNER ............................................................................ 22
12. VALVES SUPPLIED TO EUROPEAN SITES ............................................................. 22
13.0 BIBLIOGRAPHY .................................................................................................. 23
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1.0 INTRODUCTION
This document specifies general requirements for valves. It contains requirements for
materials, heat treatment, corrosion testing, welding, NDE and certification. This PMRC
MAR shall apply in addition to the applicable PMRC datasheet.
2.0 SUMMARY OF CHANGES
This document is the first issuance of PMRC MAR (2014).
3.0 MATERIAL REQUIREMENTS
3.1 CHEMICAL COMPOSITION
3.1.1 General
Unless specified otherwise, the restrictions in the chemical composition
contained in clauses 3.1.2 through 3.1.6 apply to the pressure containing parts
of the valve (body, bonnet and cover) and the stem for each valve.
3.1.2 Carbon steel
Carbon steel forgings to ASTM A 105 and to ASTM A 350 Grade LF2 Class 1
shall have the following restrictions in their chemical composition:
The carbon content shall not exceed 0.23 %.
The carbon equivalent (CE) shall not exceed 0.43.
Carbon steel castings to ASTM A 216 Grades WCB and WCC and to ASTM
A 352 Grade LCC shall have the following restrictions in their chemical
composition:
1. The carbon content shall not exceed 0.25 %.
2. The carbon equivalent (CE) shall not exceed 0.43.
The carbon equivalent (CE) shall be calculated with the following formula:
Mn Cr Mo V Ni Cu
CE C
6 5 15
3.1.3 1.25Cr‐0.5Mo steel
The chemical composition of 1¼Cr‐½Mo forgings to ASTM A 182 Grade F 11
base materials shall meet the following additional chemical requirements by heat
analysis:
Element C P S Cu Ni X‐bar
Max 0.15% 0.007wt% 0.007wt% 0.20% 0.30% 14 ppm
allowed
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X‐bar shall be calculated with the following formula:
X bar with P, Sb, Sn and As values in ppm.
Note: If meeting the above requirement leads to unacceptable lead times or cost
increase, F22 material shall be selected. F11 materials not meeting above
requirement shall not be accepted.
Unless specified otherwise, 1.25Cr‐0.5Mo castings to ASTM A 217 Grade WC6
shall have the following restriction in the chemical composition:
The phosphorous content shall not exceed 0.010 %.
3.1.4 2.25Cr‐1.0Mo steel
Unless specified otherwise, the restrictions in the chemical composition of
2.25Cr‐1.0Mo forgings to ASTM A 182 Grade F22 shall be one of the following two
options:
1. The carbon content shall not exceed 0.14 % and both the phosphorous and
sulphur content shall not exceed 0.010 %.
2. The J‐factor shall be calculated in accordance with API 934 and shall not exceed
120.
3.1.5 Austenitic stainless steel
Carbon content up to 0.08% by mass is acceptable in forgings to ASTM A182
F316 and castings to ASTM A351 Grade CF8M under the following conditions:
a) For flanged valve bodies, without welded bonnet or other fabrication welds,
where the valve design temperature i≤ 427 ⁰C (≤ 800 ⁰F), cast to ASTM A
351: if additional requirement S11 is applied (post weld solution heat
treatment after casting repairs), or
b) If the material is stabilised with niobium through substitution with ASTM A
351 grade CF10MC, or
c) If the material is stabilised with titanium through substitution with ASTM A
182 grade F 316Ti, or
d) For components that contain no welds: if the valve design temperature is≤
427⁰C (≤ 800 ⁰F).
3.1.6 Duplex stainless steel
Duplex stainless steel forgings shall have the following restrictions in the
chemical composition:
For “22Cr” duplex (austenitic‐ferritic) stainless steels, the Pitting Resistance
Equivalent (PREN) shall be 30 or higher and the Mo mass fraction (wMo) 1.5% or
higher.
For “25Cr” super duplex (austenitic‐ferritic) stainless steels, the Pitting
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Resistance Equivalent (PREN) shall higher than 40.
The PREN shall be calculated as given in Equation (1):
PREN = wCr + 3.3(wMo + 0.5wW) + 16wN (1)
where;
wCr is the mass fraction of chromium in the alloy, expressed as a percentage
mass fraction of the total composition;
wMo is the mass fraction of molybdenum in the alloy, expressed as a
percentage mass fraction of the total composition;
wW is the mass fraction of tungsten in the alloy, expressed as a percentage
mass fraction of the total composition;
wN is the mass fraction of nitrogen in the alloy, expressed as a percentage
mass fraction of the total composition.
Per lot, one product analysis shall be made. One lot is defined as a group of
valves manufactured for one heat of material and heat treatment batch.
3.2 HEAT TREATMENT
3.2.1 General
All heat treatment procedures shall be subject to a statistical process control to
ensure that the final material properties comply with the applicable material
standard and this PMRC MAR.
Post‐weld heat treatment (PWHT) shall be performed as required in the applicable
material standard. Unless specified otherwise, PWHT only applies to all welds
affecting the integrity of the pressure retaining boundary and does therefore not
necessarily apply to tack welds, seal welds or attachment welds such as those for
backseat bushings, seat rings, lifting lugs and auxiliary connections.
3.2.2 Carbon steel
Carbon steel forgings to ASTM A 105 shall be furnished in the normalised condition.
3.2.3 Cr‐Mo steel
Cr‐Mo forgings and castings shall be furnished in the normalised and tempered
condition.
3.2.4 Austenitic stainless steel
Austenitic stainless steel forgings and castings shall be furnished in the solution
heattreated condition.
If specified for type 321, 321H, 347, 347H, 348, 348H, CF8C or CF10MC,
austenitic stainless steel forgings and castings shall be subjected to a
stabilisation heat‐treatment with a stabilising temperature between 870 °C
(1598 °F) and 900 °C (1652 °F), and a duration of 4 hours. The use of 321H and
347H requires the approval from the Owner as specified in PTS 15.01.01.
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3.2.5 Duplex stainless steel
The heat treatment of duplex (austenitic ‐ ferritic) stainless steel forgings and
castings shall comply with the following:
General
a) Forgings or castings shall be solution annealed at a temperature that is
within the temperature range specified in the applicable material standard, for
a minimum of one hour per inch of thickness or a minimum of two hours,
whichever is the greater.
b) The thickest section of the forging or casting shall be used to determine the
soak time at the solution annealing temperature.
c) Immediately after solution annealing, forgings or castings shall be water
quenched.
d) The Manufacturer may submit an alternative solution annealing procedure for
review and approval by the Owner.
3.2.6 13Cr steel
The heat treatment of 13Cr castings to ASTM A 487‐CA6NM shall consist of
normalising and double tempering as follows:
a) Austenitising at 1010 °C (1850 °F) to 1065 °C (1950 °F), followed by air‐
cooling to room temperature.
b) Intermediate tempering at 675 °C (1250 °F) ± 15 °C (± 25 °F), followed by air‐
cooling to room temperature.
c) Final tempering at 610 °C (1125 °F) to 620 °C (1150 °F), followed by air‐
cooling to room temperature.
3.2.7 Nickel alloys
Nickel alloy castings to ASTM A 494 Grade N‐7M shall be solution annealed
at1180 °C [‐10 °C / +20 °C] (2156 °F [‐18 °F / +36 °F]), after PWHT. Annealing
at other temperatures may be accepted, provided the qualification tests show
that this leads to a fully solution annealed structure that is free of precipitates.
This is subject of approval by the Owner.
If specified, PWHT for Alloy 400 forgings to ASTM B 564 UNS N04400 or
castings to ASTM A 494 Grade M35‐1, shall be carried out at 590 °C (1094 °F)
for at least 1 hour.
3.3 IMPACT TESTING
General
Impact testing is required where this is a requirement of the applicable
standard specification or design code such as ASME B31.3. Exemption from
impact testing or relaxation of the minimum impact toughness requirement as
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permitted in the design codes, when the design stress is reduced relative to the
allowable stress, shall only be invoked with the approval of the Owner.
A minimum of one impact test, comprising a set of three specimens, shall be
performed on a representative test bar of each heat of the material in the final
heat‐treated condition.
Test specimens shall be cut from a separate or attached block taken from the
same heat, reduced by forging where applicable, and heat‐treated to the
same heat treatment, including stress‐relieving, as the product materials, except
that it is not necessary to retest pressure‐containing parts stress‐relieved at or
below a previous stress‐relieving or tempering temperature.
The long axis of the test specimens shall be oriented transverse to the axis of the
forging/casting or roling direction of the block. Longitudinal samples shall only be
used, if transverse samples are not possible.
Impact test specimens shall be located at mid thickness.
For weldments, impact test specimens shall be taken across the full cross section
of the weld including weld metal, HAZ, fusion line (FL) and FL+5mm.
Where sub‐size specimens are permitted or necessary, the required absorbed
energy shall be adjusted accordingly by the ratio of the specimen width parallel to
the notch to the width of a full‐size specimen (10mm) as indicated in ASTM A370.
Additional requirements for quality control purposes are given here for
certain valve materials.
For the impact values of material types and grades listed below, below listed
values shall prevail.
Carbon steel
Impact testing is required for pressure containing parts of low temperature
carbon steel forgings and castings, in cases indicated in the ASTM standard or
the applicable design code.
Impact test results as an average of three tests shall be at least 27 J (20 ft.lbs) for
standard size specimens (10 mm x 10 mm) at the minimum design temperature.
Only one result may be lower than 27 J (20 ft.lbs), but it shall be at least 21 J (15
ft.lbs).
If nuts of grade 4 or 7M are specified, ASTM A194 Supplementary Requirement
S3 shall apply.
Duplex stainless steel
Impact testing is required for pressure containing parts of duplex (austenitic‐
ferritic) stainless steel valve materials:
Charpy impact tests shall be carried out in accordance with ASTM A 370 at a
temperature of minus 50 °C (minus 58 °F).
A set of three Charpy impact test specimens shall be taken from one
representative piece per heat treatment lot (One lot is defined as a group
of valves of same wall thickness manufactured for one heat of material and
heat treatment batch) in the final heat‐treated condition.
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If the thickness exceeds 25 mm (0.98 in), one additional set of three Charpy
test specimens shall be taken 3 mm (0.12 in) from the internal surface and
another set of three test specimens as close as possible to the outside surface.
The notch of all Charpy specimens shall be perpendicular to the main surface.
Sub‐size samples can only be applied, if standard 10 mm x 10 mm (0.39 in x
0.39 in) samples are not possible.
The acceptance criteria shall be in accordance with Table 1.
If the thickness is below 6.5 mm (0.26 in), Charpy impact testing is practically
not possible. The Owner may require additional microstructural checks in
accordance to section 2.5.
Table 1 ‐ Acceptance criteria for Charpy impact testing
Sample size Test Minimum Minimum Minimum
mm (in) direction average single single shear
impact
impact area
value value
10 x 10 Transverse 50 J* 40 J 50 %
(0.39 x (37 ft.lbs) (30 ft.lbs)
0.39)
10 x 10 Longitudinal 75 J 60 J 50 %
(0.39 x (55 ft.lbs) (44 ft.lbs)
0.39)
10 x 7.5 Transverse 40 J 30 J 50 %
(0.39 x 0.30 (30 ft.lbs) (22 ft.lbs)
10 x 7.5 Longitudinal 60 J 45 J 50 %
(0.39 x (44 ft.lbs) (33 ft.lbs)
0.30)
10 x 5 Transverse 25 J 20 J 50 %
(0.39 x (18 ft.lbs) (15 ft.lbs)
0.20)
10 x 5 Longitudinal 38 J 30 J 50 %
(0.39 x (28 ft.lbs) (22 ft.lbs)
0.20)
* impact energy of 50 J (37 ft.lbs) at minus 50 ºC (minus 58 ºF) is deemed to
meet the ASTM A923 Method B requirement of 54 J (40 ft.lbs) at
minus 46 ºC (minus 50 ºF) specified for a superduplex grade.
Martensitic stainless steel
Impact testing is required for pressure containing parts of:
Martensitic stainless steel forgings to ASTM A 182 Grade F6NM;
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Martensitic stainless steel castings to ASTM A 487 Grade CA6NM.
Impact test results for martensitic stainless steels shall be at least 27J (20 ft.lbs) at
21°C (70 °F) for standard size specimen of 10 mm x 10 mm (0.39 in x 0.39 in).
3.4 CORROSION TESTING
3.4.1 Austenitic stainless steel
All austenitic stainless steel forgings and castings shall be subject to statistical
process control, which shall include intergranular corrosion testing in accordance
with ASTM A 262, Practice E.
Bolting materials of grades B8, B8M and B8M2 shall be capable of passing an
intergranular corrosion test in accordance with ASTM A 262, Practice E.
If nuts of grade 8, 8C, 8M or 8MA are specified, the following requirements
shall apply:
The nut material shall be capable of passing an intergranular corrosion test
in accordance with ASTM A 262, Practice E.
Supplementary Requirement S1 of ASTM A194.
3.4.2 Nickel alloys
Alloy 625 forgings shall be subject to statistical process control, which shall
include intergranular corrosion testing in accordance with ASTM G 28, Method
A. The maximum allowed corrosion rate is 0.08 mm/month (0.0030 in/month).
Alloy 825 forgings shall be subject to statistical process control, which shall
include intergranular corrosion testing in accordance with ASTM A 262, Practice
C. The exposure time shall be 240 hours. The maximum allowed corrosion rate is
0.08 mm/month (0.0030 in/month). Alloy 600 and Alloy 800 forgings shall be
subject to statistical process control, which shall
include intergranular corrosion testing in accordance with ASTM G 28, Method
A. The maximum allowed corrosion rate is respectively 0.05 mm/month (0.0020
in/month) and 0.04 mm/month (0.0015 in/month).
Alternative methods are subject of approval by the Owner.
3.4.3 Duplex stainless steels
3.4.3.1 Pitting Corrosion
The material shall be capable of passing the ferric chloride test in accordance
with ASTM G 48, Method A, with the following amendments. This corrosion test
shall be performed for product qualification only. Testing shall be out on one
specimen per lot (One lot is defined as group of valves of same wall thickness
manufactured for one heat of material and heat treatment batch). If welds are part
of the valve design, a representative specimen of the weldment, including the
internal surface of the part, the internal surface of the weld root and the internal
surface of the Heat Affected Zone, as applicable, shall be tested as well.
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The test temperature for “22Cr” duplex (ferritic‐austenitic) stainless steel shall
be 25°C (77°F).
The test temperature for “25Cr” superduplex (ferritic‐austenitic) stainless steel
shall be 40°C (104°F).
The temperature variation shall not exceed ± 0.5°C (± 0.9°F).
The surface finish of the test face shall be ‘as‐produced’. Cut faces shall be
ground to 1200 grit.
The evaluation of results shall be via weight loss measurement and macroscopic
investigation of the surface. Macrographs obtained by low magnification
microscopy shall be provided.
The acceptance criteria shall be a weight loss < 4.0 g/m2 and no initiation of
localized corrosion > 0.025 mm at the test face. Note that only corrosion (e.g.
pitting) at the test face counts. If the weight loss is > 4.0 g/m2 and it can be
positively identified that this is only due to corrosion at the cut faces, the test will
be invalid. In this case retesting shall be carried out on replacement specimens.
3.4.3.2 Stress Corrosion Cracking
If specified by the Owner, stress corrosion cracking tests in accordance with
ASTM G 38, ASTM G 39 or ISO 15156‐3 shall be carried out. Specimens shall
be prepared such that the inner surface of the piece will be loaded at proof
stress and exposed to the test environment in the as‐produced condition. The
dimensions of the specimen, test environment and conditions shall be based
on agreement between the Manufacturer and the Owner.
This test is a product qualification test only.
3.4.4 Other materials
For other materials, where intergranular corrosion could be a concern, statistical
process control shall be applied, including intergranular corrosion testing with a
relevant test. The procedure and acceptance criteria shall be submitted to the
Owner for approval.
3.5 MICROSTRUCTURE DETERMINATION
The microstructure of duplex (ferritic‐austenitic) pieces shall be determined.
3.5.1 Ferrite phase
The microstructure and percentage of ferrite phase shall be determined by
point counting in accordance with ASTM E 562 on one test specimen from one
piece representing each lot (One lot is defined as a group of valves of the
same wall thickness manufactured for one heat of material and heat treatment
batch). Ferrite phase testing shall be carried out in accordance to TABLE‐2. If
welds are present, a representative weld shall be examined as well.
The ferrite content shall be in the range of 40 % ‐ 60 % for the parent material
and Heat Affected Zone (HAZ) and in the range of 30 % ‐ 60 % for the weld metal.
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3.5.2 Detrimental phases
The microstructure shall be examined for detrimental phases in accordance
with ASTM A 923 Method A on one test specimen from one piece representing
each lot (One lot is defined as a group of valves of same wall thickness
manufactured for one heat of material and heat treatment batch). If welds are
present, a full cross section of the weld (including weld metal, fusion line and HAZ)
shall be examined on one test coupon as well. The etching method shall be suitable
to reveal inter‐metallic phases (such as sigma phase) and precipitates (such as
nitrides).
The microscructure shall classify as “unaffected structure” as per section 6 of ASTM
A 923. The microstructure shall display a uniform ferrite and austenite phase
distribution and shall have no continuous precipitates at the grain boundaries.
In addition, the sigma phase content shall not exceed 0.5 %, while the total
of intermetallic phases shall not exceed 1.0 %. If these criteria are not met, the
piece shall be rejected and each piece of the lot investigated.
3.6 For duplex stainless steel, tensile tests shall be performed in duplicate on
specimens representing each heat treatment lot (One lot is defined as a group
of valves manufactured for one heat of material and heat treatment batch). Testing
shall be carried out in accordance with ASTM A370 at room temperature.
Specimens shall be taken mid wall thickness in transverse direction. If weld are
present, additional cross weld tensile tests shall be carried out on test coupon.
The requirements of the applicable materials standard shall be met.
3.7 Hardness measurements shall be carried out on one representative specimen
per heat treatment lot (one lot is defined as a group of valves of the same wall
thickness manufactured for one heat of material and heat treatment batch).
Trajectories of 5 hardness measurements shall be carried out at mid‐wall, 2
mm form the inner surface and 2 mm from the outer surface. If welds are
present, additional cross weld hardness measurements trajectories shall be
made on test coupon, which shall include readings of base metal, weld metal,
HAZ fusion line(FL) and FL+5mm. The requirements of the applicable
materials standard shall be met.
4.0 WELDING AND HARD FACING REQUIREMENTS
4.1 Internal valve parts of 13Cr shall not be tack welded or seal welded.
4.2 For butt‐welding soft‐seated valves, the Manufacturer shall advise the field
welding requirements.
4.3 All static and dynamic sealing surfaces of carbon steel or low alloy steel intended
for use with thermo plastic chevron or lip seals shall be weld‐over layed with grade
316L stainless steel, or Alloy 625 material per PMRC MAR VA/126. For such areas,
surface finish shall be Ra < 0.2 µm
4.4 Hard facing shall comply with the following requirements:
4.4.1 Hard facing material
For tungsten carbide hard facing, hard facing material shall be 83% tungsten
carbide and 17% cobalt as metallic binder.
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For chromium carbide hard facing, hard facing material shall be 75% chromium,
25% nickel.
4.4.2 Hard facing deposit thickness
Sprayed deposit thickness shall be 0.25 mm (0.01 in) minimum, for finish ground
minimum thickness of 0.13 mm (0.005 in).
4.4.3 Pre‐Treatment
Components shall be pre‐machined to achieve a surface roughness of 0.8 µm
Ra.
Total surface area of the components shall be completely degreased by
immersion and brushing in solvent degreaser.
Component surfaces to be sprayed shall be grit‐blasted using
compressed air at a maximum supply pressure of 4 barg (60 psig),
extend grit blasting12.5 mm (0.5 in) beyond the areas to be hardfaced
for port s≥z DN 50 (≥ NPS 2) and 3 mm (0.125 in) for port sizes < DN 50 (<
NPS 2).
4.4.4 Thermal Spraying
The process shall be of type “High Velocity Oxygen Fuel” (HVOF) type, or
equivalent with the same properties.
All thermal spraying shall be carried out under optimal conditions. The
component shall be coated immediately after heating and grit blasting while the
component is still at a temperature well above the dew point. All seating areas of
the valves shall be coated as a minimum. However, for ball valves, the complete
spherical part of the ball in contact with the seat along the full travel shall be
coated.
4.4.5 Vacuum sealing
No vacuum sealing of sprayed surfaces shall be employed.
4.4.6 Finishing
All the coated parts shall be ground and lapped. The planarity for gates and the
out of roundness for ball shall be according to the value indicated on the
engineering drawing.
4.4.7 Surface finish testing
The surface on the finished components shall be tested.
Acceptance criteria: The maximum roughness value shall be Ra = 0.15 µm.
The surface sealing contact between ball or gate and seats will be integral,
without any circumferential failure or scratch.
4.4.8 Non Destructive Examination (NDE)
All the coated surfaces shall be 100% visually examined and shall be free from
pores and cracks.
In addition, all the coated surfaces and substrate areas 12.5 mm (0.5 in) beyond
coating shall be 100% liquid penetrant examined in accordance with Article 6,
ASME V. The acceptance criteria shall be in accordance with QW 195.2, ASME IX.
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4.5 Unless otherwise specified, the minimum finished thickness of the welded‐on hard
facing material shall be 1.0 mm (0.039 in).
5.0 VALVES MANUFACTURED FROM BAR MATERIAL
Valves may be manufactured from bar material, within the limits specified in ASTM A 961,
except that bar material shall not be used for valve sizes > DN 100 (> NPS 4). The extent of
NDE for these valves shall be the same as that for forged valves.
6.0 LIFTING POINTS
The Manufacturer shall ensure that the valve is capable of being lifted (e.g. provided with
lifting points, if necessary).
7.0 PUP PIECES
If pup pieces are specified, the following requirements shall apply unless specified
otherwise:
Their length shall be 200mm (8 in) for sizes < DN 50 (< NPS 2), 400 mm (16 in)
for sizes ≤ DN 300 (≤ NPS 12) and 800 mm (32 in) for sizes > DN 300 (> NPS 12).
The purchase order shall state the wall thickness and material.
For soft‐seated valves, the pup pieces shall be attached to the valve before the
valve internals are installed.
Transition tapers shall not be steeper than 1:4 and shall comply with ASME
B31.3, Figure 328.4.3.
The heat treatment batch number shall be clearly marked on the pup piece.
If a pup piece is to be attached to a soft‐seated valve by a manufacturer or by
a party other than the Manufacturer, the Manufacturer shall provide the
welding procedure, welding procedure qualification records, welder
qualification records and NDT procedures
8.0 NON‐DESTRUCTIVE EXAMINATION
8.1 INSPECTION SCOPE
The quality of valves shall be such that when examined in accordance with 8.2.1
and 8.2.2, the valves shall conform to the acceptance criteria specified in 8.2.3.
As a minimum, valves shall be subject to Non‐Destructive Examination (NDE)
in accordance with their Inspection Category (IC). These Inspection Categories
are determined on the basis of pressure class, material, valve size and service.
Based on the information provided in the PMRC datasheet, purchase order or
requisition sheet, the Manufacturer shall determine the appropriate Inspection
Category (IC‐I, IC‐II, IC‐III or IC‐IV) for each valve, by applying the decision tree
given in Figure 1. The extent of NDE per Inspection Category shall be in accordance
with Table 1.
Regardless of the sampling specified in section 8.2.4, a prototype casting shall be
fully inspected and tested by the manufacturer in accordance to the
following
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examinations:
i) Visual examination
ii) RT or UT of critical areas (Critical sections of pressure containing parts (body
and bonnet / cover) as determined by radiographic examination
requirements for special class valves as defined by ASME B16.34) of pressure
containing parts
iii)MP or LP of entire surface of pressure containing parts. Liquid
Penetrant examination shall be considered on non‐magnetic materials.
The above mentioned examinations shall be exceuted in accordance to 8.2.
8.2 EXECUTION
8.2.1 Methods
The following requirements shall apply:
i. Visual examination
Examination shall be carried out in accordance with ASME Section V, Article 9.
ii. Penetrant testing (LP)
Examination shall be carried out in accordance with ASME Boiler and
Pressure Vessel Code, Section V, Article 6. For stainless steel and CRA
valves, LP examination shall be performed only after thorough cleaning as
per ASTM E165, A1.1.1.8.
iii. Magnetic‐particle testing (MP)
Examination shall be carried out in accordance with ASME Boiler and
Pressure Vessel Code, Section V, Article 7.
iv. Radiographic testing (RT) of castings
Examination shall be carried out in accordance with ASME B16.34‐2004,
Appendix‐I.
v. Radiographic testing (RT) of welds
Examination shall be carried out in accordance with ASME Boiler and
Pressure Vessel Code, Section V, Article 2.
vi. Ultrasonic testing (UT) of plate
Examination shall be carried out in accordance with ASTM A388, ASTM A435
or ASTM A577, as applicable.
vii. Ultrasonic testing (UT) of castings
Examination shall be carried out in accordance with ASME B16.34‐2004,
Appendix‐IV.
viii. Ultrasonic testing (UT) of welds
Examination shall be carried out in accordance with ASME Boiler and
Pressure Vessel Code, Section V, Article 4.
ix. Ferrite Number (FN) testing
Examination shall be carried out in accordance with ISO 8249. Alternative
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methods are subject of approval by the Owner.
x. Hardness testing
Examination shall be carried out in accordance with ASTM E 110.
xi. All other examinations shall be carried out in accordance with ASME B16.34.
8.2.2 Execution
The following requirements shall apply:
i. Unless specified otherwise, NDE shall be carried out after completion
of heat treatment.
ii. Visual examination shall be conducted on the entire, visible, internal and
external surface area of the valve components.
iii. Magnetic Particle (MP) and Liquid Penetrant (LP) examinations shall be
carried out on surfaces in their finished form and prior to application of
coating on accessible internal and external surfaces to the extent as
specified in Table 1. The yoke method shall be used (if possible), but
permanent magnets are prohibited.
iv. NDE personnel shall be qualified in accordance with the requirements
specified in ASNT SNT‐TC‐1A, ISO 9712 or EN 473 Level II as a minimum.
Other qualifications are subject of approval by the Owner.
v. Hardness testing shall be executed as follows:
• At least 1 reading per weld for valves ≤ DN 100 (≤ NPS 4).
• At least 2 readings per weld for valves 150 ≤ DN ≤ 300 (6 ≤ NPS ≤ 12).
• At least 1 reading every 400 mm (16 in) of weld length for valves >
DN 300 (> NPS 12).
Hardness testing applies to pressure retaining welds only (i.e. attachment of
flanges to the valve body, body‐to‐bonnet or body‐to‐cover connection).
8.2.3 Acceptance criteria
The following requirements shall apply:
i. Unless specified otherwise, acceptance criteria for NDE methods shall
be in accordance with ASME B16.34.
ii. Penetrant testing (LP)
Acceptance shall be in accordance with ASME Boiler and Pressure Vessel
Code, Section VIII, Division 1, Appendix 8, except:
• for castings and non‐machined overlay relevant indications (rounded
and linear) of less than 5 mm are acceptable;
• for machined overlay there shall be no indications in the seal areas
iii. Magnetic‐particle testing (MP)
Acceptance shall be in accordance with ASME Boiler and Pressure Vessel
Code, Section VIII, Division 1, Appendix 6, except:
• For castings relevant indications (rounded and linear) of less than 5 mm
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are acceptable.
iv. Radiographic testing (RT) of castings
Acceptance shall be in accordance with ASME B16.34‐2004, Appendix‐I.
v. Radiographic testing (RT) of welds
• For linear indications, acceptance shall be in accordance with ASME
Boiler and Pressure Vessel Code, Section VIII, Division 1, UW‐51;
• For rounded indications, acceptance shall be in accordance with
ASME Boiler and Pressure Vessel Code, Section VIII, Division 1,
Appendix 4.
vi. Ultrasonic testing (UT) of plate
Acceptance shall be in accordance with ASTM A388, ASTM A435 or ASTM
A577, as applicable.
vii. Ultrasonic testing (UT) of castings
Acceptance shall be in accordance with ASME B16.34‐2004, Appendix‐IV.
viii. Ultrasonic testing (UT) of welds
Acceptance shall be in accordance with ASME Boiler and Pressure Vessel
Code, Section VIII, Division 1, Appendix 12.
ix. Visual examination
The acceptance criteria for visual examination of forgings shall be in
accordance with the applicable ASTM standard, while the acceptance
criteria for visual examination of castings shall be in accordance with MSS
SP‐55.
x. Hardness testing
Unless specified otherwise, hardness testing shall have the following
acceptance criteria:
• The hardness of base metal, welds and Heat Affected Zones (HAZ) of
pressure containing parts (body, bonnet or cover) manufactured of
carbon steel and low alloy steels shall not exceed 248 HV10.
• The hardness of the different base metals shall be as follows :
• Duplex SS ≤ 310HV10
• Super duplex SS ≤ 330HV10
• Super austenitic SS ≤ 340HV10
• Alloy 625 ≤ 320HV10 of 330 HV10 to 450 HV10.
• The hardness of Stellite 6 weld overlay shall be in the range of 330
HV10 to 450 HV10.
• The hardness of 13 Cr internals shall be as follows :
• 13Cr ≤ 248HV10
• 13Cr 4Ni ≤ 255HV10
• 17‐4PH ≤ 320HV10
• The hardness indentations shall be avoided on any sealing or sliding
surfaces.
xi. Ferrite Number testing
The Ferrite Number of the deposited weld metal of all austenitic stainless
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steel welds shall be in the range of 3FN to 8FN.
Acceptance criteria for corrosion resistant weld overlay materials shall be
in accordance with PMRC MAR VA/126.
8.2.4 Sample strategy and lot acceptance
Unless specified otherwise, the lot for each inspection campaign, from which
the test samples are drawn, is defined as all valves part of the same purchase order
and purchased from a single manufacturing location.
Based on the decision tree of Figure 1, the lot shall be divided into sub‐lots per
Inspection Category (IC). Table 2 then gives the percentage of NDE per Inspection
Category and thus per sub‐lot.
In case the percentage of the lot to be inspected is < 100 %, the sample size
shall be rounded‐up to the next whole number. In that case samples shall be drawn
from the sub‐lot of valves at random. However, if that sub‐lot consists of various
sizes, pressure classes, then sampling shall be applied in such a way that it covers
the entire production range from that lot. In addition, in case the sub‐lot is
manufactured from different heats, at least 1 valve per heat shall be examined.
In the event that any of the examinations do not meet the acceptance criteria,
the failed valve(s) shall be repaired, tested and re‐examined by the same method
and the re‐examination shall include additional valves from the same sub‐lot. The
sampling plan and procedure for the re‐examination shall follow ISO 2859/2:1985,
Procedure A, Limiting Quality 32% (Table A).
If the number of nonconforming valves found in the sample is greater than
the acceptance number (AC), the lot is unacceptable. In that case all valves in the
sub‐lot shall be re‐examined.
Notwithstanding that the lot is accepted, any nonconforming valves found
during examination, whether forming part of the sample or not, shall be repaired,
tested and re‐examined.
The entire lot shall be accepted if all samples meet the requirements.
8.3 DEFECT REMOVAL AND WELD REPAIR
Unless specified otherwise, defect removal and repair shall be in accordance with
ASME B16.34, Section 8.4.
Austenitic stainless steel, duplex or nickel alloy valves may be repaired by welding,
in which case a further solution heat treatment shall be performed after the repair
in accordance with ASTM A 743. Repair welding of duplex valves is only allowed if
specifically approved by the Owner.
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Start here
Yes
Is any of the following casting /forging material specified: Temperature, max:
xii. Ferritic Steel > 435 °C IC-IV
(CS, Cr-Mo Steel, ferritic martensitic SS) (> 815 °F)
No
Yes
Is any of the following casting /forging material specified: Temperature, max:
> 450 °C IC-IV
xiii. Austenitic Stainless Steel (> 840 °F)
xiv. Nickel-base alloy
No
No
No
IC-I
No IC-I
No IC-I
No
IC-I
Size:
<= Class 300 > DN 600 Yes
(NPS 24) IC-II
No
IC-I
Figure 1: Decision tree for selecting the appropriate Inspection Category
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Table 2 ‐ Extent of NDE on valves
1 RT = Radiography ; UT = Ultrasonic ; MP = Magnetic Particle ; LP = Liquid Penetrant
2 Critical sections of pressure containing parts (body and bonnet / cover) as determined by radiographic
examinationrequirements for special class valves as defined by ASME B16.34.
3 Liquid Penetrant on non‐magnetic materials.
4 X = 100 % for austenitic stainless steel with an maximum design temperature > 450 °C (> 842 °F) and/or a
minimum design temperature < minus 101 °C (< minus 150 °F) and/or in ASME Class 1500 and higher.
X = 5 % for other austenitic stainless steel, , nickel based alloys, or for valves specified for Severe Cyclic
Service.
X = For duplex stainless steel, see section 2.5
5 Y = 100 % for valves, as specified as for Severe Cyclic Service.
Y = 5 % for valves made of carbon steel, C‐Mn or Cr‐Mo steels in ASME Class 1500 and higher.
Y = 5 % for valves made of carbon steel, C‐Mn or Cr‐Mo steels in ≤ ASME Class 900 and for either of the
following services: hydrogen, hydrofluoric acid (HF), sour, caustic soda, sulfuric acid, chlorine or for valves with
a minimum design temperature < minus 29 °C (< minus 20 °F).
Y = 5 % for valves made for sour service or in case the material specification covers any hardness restriction.
Y = For duplex stainless steel, see section 2.7
6 For welded bonnet gate and globe check valves, DN 50 (NPS 2) and smaller (designed to API 600, API 602,
ISO15761) 100% MP or LP examination.
7 For stainless steel and CRA valves, etching shall be performed (see ASTM E165, Annex A1.1.1.8)
9.0 DOCUMENTATION
The Manufacturer shall provide documentation prior to shipment.
Computerised data or photocopies of originals, which are verified and signed by
the QA/QC department, may be provided instead of originals.
All documentation shall be in English or accompanied by a certified translation in
English.
Unless specified otherwise, all documentation shall be stored for at least 10 years
and shall include the following:
1. Purchase order and identification of valves by serial number or Manufacturer’s
code.
2. Material test reports and inspection certificates, traceable by heat number
to the foundry or mill.
3. NDE reports, including sketches, if necessary, showing the locations of
examination, traceable by heat or serial number. The retention period for
NDE reports shall be 5 years. The retention period for radiographs shall be at
least 12 months.
4. For duplex stainless steel parts, heat treatment records shall be provided.
5. Listing of applicable and authorised concessions, waivers and/or material
substitutions.
6. Listing of applicable manuals (e.g. assembly or maintenance manuals).
10. CERTIFICATION
with ISO 10474 type 3.1.B or EN 10204 type 3.1.
2. All non‐metallic materials shall have a certificate of compliance in
accordance with ISO 10474 type 2.1 or EN 10204 type 2.1.
3. All testing and examination shall have an inspection certificate in
accordance with ISO 10474 type 3.1.B or EN 10204 type 3.1.
4. The finished valve shall have an inspection certificate in accordance with ISO
10474 type 3.1B or EN 10204 type 3.1, demonstrating that it complies with all
requirements.
10.2 Third party certification
The Product Acceptance Test shall be certified by the relevant authorised third
party inspection company.
11. WITNESSING BY THE OWNER
The Owner shall specify if, and to what extent, he or his designated
representative will witness the Manufacturer’s inspections and tests and/or will
perform a document review before shipment.
12. VALVES SUPPLIED TO EUROPEAN SITES
If the valve is supplied to an end user in a European member state or country in
the European Free Trade Association, the following requirements shall apply:
i. All valves shall meet the requirements of the Pressure Equipment Directive
(PED) 97/23/EC (May 1997).
ii. Low temperature carbon steels valves shall be impact tested at a
temperature of minus 50 °C (minus 58 °F). The absorbed energy, as given in
the steel certificate, shall exceed 27J for standard size specimens (10 mm x 10
mm). Alternatively, the impact tests may be carried out at minus 46 °C (minus
50 °F) but the impact values shall be at least 33J for standard size specimens.
iii. Steel valves > DN 25 (> NPS 1) shall be subject to conformity assessment
procedures applicable to Category III requirements and certified accordingly.
iv. All safety valves and valve actuator assemblies, designed as safety accessories
shall be subject to conformity assessment procedures applicable to
Category IV requirements and certified accordingly.
v. The inspection certificates shall be in accordance with EN 10204.
vi. Materials shall comply with the requirements of Para 4, Annex 1, 97/23/EC.
vii. If specified, valves shall meet the relevant requirements of the Potentially
Explosive Atmospheres Directive (ATEX) 94/9/EC (March ’94).
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13.0 BIBLIOGRAPHY
In this PMRC MAR, reference is made to the following Standards/Publications. Unless
specifically designated by date, the latest edition of each publication shall be used, together
with any supplements/revisions thereto:
PETRONAS STANDARDS
Valves With Corrosion Resistant Alloy PMRC MAR VA/126
(CRA) Weld Overlay Cladding
Metallic Materials – Selected Standards
PTS 15.01.01
AMERICAN STANDARDS
Materials and Fabrication Requirements for API RP 934 (1st Edition):2010
2‐1/4Cr‐1Mo and 3Cr‐1Mo Steel Heavy Wall
Pressure Vessels for High Temperature, High
Pressure Hyrdogen Service
Issued by:
American Petroleum Institute
Publications and Distribution Section
1220 L Street Northwest
Washington DC 20005
USA
Valves ‐ Flanged, threaded, and welding end ASME B16.34:2009
Process Piping ASME B31.3:2010
ASME Boiler and Pressure Vessel Code:
Section V – Nondestructive ASME V
examination
Section VIII ‐ Pressure vessels ‐ ASME VIII Div. 1:2010
Division 1 ‐
Rules forconstruction of pressure
vessels
Section IX ‐ Qualification standard for ASME IX:2010
welding and brazing procedures, welders,
brazers, and welding and brazing operators
Issued by:
American Society of Mechanical Engineers
ASME International Three Park Avenue,
M/S 10E New York,
NY 10016
USA
Recommended Practice No. SNT‐TC‐1A ASNT SNT‐TC‐1A
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Issued by:
American Society for Nondestructive Testing
PO Box 28518
1711 Arlingate Lane
Columbus, OH 43228‐0518
USA
Standard Test Method for Detecting Detrimental ASTM A 923:2008
Intermetallic Phase in Duplex Austenitic/Ferritic
Stainless Steels
Standard Specification for Common ASTM A 961:2012
Requirements for Steel Flanges, Forged Fittings,
Valves, and Parts for Piping Applications
Standard Specification for Castings, Iron‐Nickel‐ ASTM A 990:2011
Chromium and Nickel Alloys, Specially Controlled
for Pressure Retaining Parts for Corrosive Service
Standard Test Method for Indentation Hardness ASTM E 110:2010
of Metallic Materials by Portable Hardness
Testers
Standard Test Method for Determining Volume ASTM E 562:2011
Fraction by Systematic Manual Point Count
Standard Test Methods of Detecting Susceptibility ASTM G 28‐02 (Reapproved 2008)
to Intergranular Corrosion in Wrought, Nickel‐
Rich Chromium‐Bearing Alloys
Standard Practice for Making and Using C‐Ring ASTM G 38‐01 (Reapproved 2007)
Stress‐Corrosion Test Specimens
Standard Practice for Preparation and Use of ASTM G 39‐99 (Reapproved 2011)
Bent‐ Beam Stress‐Corrosion Test Specimens
Standard Test Methods for Pitting and Crevice ASTM G 48:2011
Corrosion Resistance of Stainless Steels and
Related Alloys by Use of Ferric Chloride Solution
Quality Standard for Steel Castings and Forgings MSS SP‐54
for Valves, Flanges, and Fittings and Other Piping
Components Radiographic Examination Method
Quality standard (visual method) for steel castings MSS SP‐55
for valves, flanges and fittings and piping
Quality Standard for Ferritic and Martensitic Steel MSS SP‐94
Castings for Valves, Flanges, Fittings, and Other
Piping Components Ultrasonic Examination
Method
Issued by:
Manufacturers Standardisation Society
of the Valve and Fittings Industry
127 Park Street, N.E.,
Vienna, VA, 22180‐4602
USA
EUROPEAN STANDARDS
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Directive of the European Parliament and of the 97/23/EC
Council on the Approximation of the Laws of the
Member States Concerning Pressure Equipment
NOTE: Commonly known as the European
Pressure Equipment Directive(PED
Issued by:
EU/EC ‐ European Union/Commission Legislative Documents 175 Rue
De La Loire Brussels,
Belgium
INTERNATIONAL STANDARDS
Sampling procedures for inspection by attributes ISO 2859/2:1985
–Part 2: Sampling plans indexed by limiting quality
(La) for isolated lot inspection
Welding ‐ Determination of Ferrite Number (FN) ISO 8249
in Austenitic and Duplex Ferritic‐Austenitic Cr‐Ni
Stainless Steel Weld Metals ‐ Second Edition
Non‐destructive testing — Qualification and ISO 9712
certification of personnel
Steel and Steel Products ‐ Inspection Documents ISO 10474
Petroleum and Natural Gas Industries – Pipeline ISO 14723
Transportation Systems ‐ Subsea Pipeline Valves
Petroleum and natural gas industries — Materials ISO 15156‐3
for use in H2S‐containing environments in oil and
gas production — Part 3: Cracking‐resistant CRAs
(corrosionresistant alloys) and other alloys
Issued by:
ISO Central Secretariat
1, ch. de la Voie‐Creuse
Case postale 56
CH‐1211 Genève 20
Switzerland