Professional Documents
Culture Documents
1. Scope:
This specification covers the requirements for design, preparation of detail drawing,
manufacture, assembly, inspection, shop testing, packing and delivery of double eccentric
wafer type stainless steel butterfly valves of ANSI 150 lbs. rating with pneumatic actuators &
manual override, Gear actuator, solenoid valves, limit switches, companion flanges, bolts,
nuts & gaskets.
3. General Requirements:
3.1. Equipment covered under these specifications are required to have high degree of
reliability, it is absolutely necessary to have proven design, excellent workmanship and
proven industrial running record of similar equipment for atleast 5 years.
3.2. Materials shall be of good quality conforming to relevant ASTM standards and shall be
suitable for the service specified. Materials test certificates shall be provided wherever
applicable.
3.3. Workmanship shall be in accordance with the best practice, adequate to ensure satisfactory
operation, service life and ease of maintenance in accordance with the provisions of this
specification.
4.1. Valves:
• Valves of wafer type construction sized for sandwiching between flanges to ANSI 150
lbs rating shall be offered. Two types of valves are required:
• It shall be designed for high degree of leak tightness past the disc and also along the
stem. Leakage class shall be class I /Rate A as per BS 6755-I. It shall be engineered for
drip-tight shut off in either direction at negative pressure.
• Seal ring on disc shall be of PTFE/EPDM or better material. Sealing element shall be
fixed to disc either in groove of disc or with a retaining segment screwed to the disc. It
should be easily replaceable type.
• Disc contact with sealing surface shall be uninterrupted all along its periphery in
closed condition. No seat and disc contact shall be there in open or intermediate
position. Disc edge shall be specially profiled to make smooth close-down and open-
up movements with respect to sealing/seating surface and also make perfect 90 degree
closure.
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• Disc joint with stem shall be soundly designed while shaping and sizing disc for
minimum flow restriction resulting in high flow coefficient value, which shall be
specifically stated while quoting.
• Design providing stem gland / duel ‘O’ rings of Viton or EPDM facilitating re-packing
in situ shall be preferred. No. of ‘O’ rings shall be minimum 2 nos. each on lower and
upper stem seal.
• Feature like friction clutch that inhibits unintended rotation of stem shall be preferred.
Provision for stem locking in positions at every 10-degree of opening shall be
provided with points marked on dial. At fully closed position mechanical stop shall be
provided to prevent swing through seating surface.
• Valve shall be suitable for operation in horizontal as well as in vertical line. These
valves shall be designed for on/off.
• One pair of matching flanges with gasket, bolts & nuts for each valve of their
respective size shall be provided. Construction standard shall be as per ANSI B 16.5.
Gasket material shall be Neoprene 3 mm thick.
• The following data shall be indicated on all the valve nameplates, which shall be of
stainless steel and fixed with SS screws.
a) Valve size, Identification No.
b) Pressure and temperature rating.
c) Body material, Disc material.
d) Operating air supply pressure.
e) Direction of flow.
f) Actuators make, model and size.
g) Solenoid valve make, model and size.
h) Two blank spaces for user identification of valve
4.2. Pneumatic Actuator: Pneumatic valves shall be provided with gear actuator as per
following requirement:
• The actuators of compact design and repute make shall be offered and shall be
subjected to final approval of the purchaser.
• It shall provide adequate margin of torque over valve torque throughout the range
while operating air pressure is not more than 4.0 Kg/cm2.
• All pneumatic actuator shall be double acting type i.e air to open and air to close. The
operating air pressure required shall not be more than 4.0 Kg./cm2.g. However the
actuators shall be capable to withstand 7.0-kg/cm2g-air pressure.
• The actuator body shall be corrosion resistant hard anodized aluminum with stainless
steel fasteners optionally body of S.S.304 material shall also be offered. Piston shall be
die cast Aluminum alternatively of SS 304. There should not be any leakage through
pinion. Pinion shall be electroless Nickel-plated and supported on ball bearings.
Positive sealing shall be achieved by at least two ‘O’ rings.
• All non-metallic parts shall be preferably PTFE / Viton meeting higher temperature
requirement.
• Valve mounting provided shall be as per ISO 5211 with ring for precise location.
4.3. Gear Actuator: Manual valves shall be provided with gear actuator as per following
requirement:
• Valves shall be provided with a worm gear actuator. The minimum speed ratio shall be
indicated in the offer.
• The gearbox shall be totally dust proof & waterproof.
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• Adequate lubrication shall be provided and the details shall be submitted with offer
with type & specification of lubricant.
• Stem locking provision shall be provided at every 10° of opening with points marked
on dial and mechanical stop at fully closed position.
• Bearings shall be used of reputed make and the detail of the bearing shall be provided.
• Material of construction of Gear Box body shall be cast iron & internal kinematic parts
material shall be indicated with the submitted offer.
• The gear actuator shall be provided with indicator cap with position indication
according to ISO 5211.
5.1. Valves:
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• The manufacturer for the valve parts shall carry out physical and chemical analysis and
test certificates shall be furnished to the purchaser.
• All cast/forged components of valves shall be Dye Penetrant tested for surface flaws as
per the specifications before and after machining.
• Material confirmation and/or corrosion tests shall be performed on a few valves,
picked at random, as are deemed necessary by the purchaser to test suitability for nitric
acid service by dipping the full valves in 40% nitric acid for one hour. Valves shall
then be stripped to check any sign of corrosion and tested for leak tightness. The
supplier shall provide all the facilities.
• Endurance Test: Endurance test for 1000 On/Off cycle shall be demonstrated for one
valves of each size before hydraulic and pneumatic test. The valve shall retain its seat
and stem leak tightness all through the endurance test. The valve lot shall be
acceptable after successful leak tightness test. In case of failure 2 more valves per
service shall be put to cycle tests. Necessary test certificates shall be provided.
• Shell Test: The hydrostatic shell test and disk strength test pressure shall be the gauge
pressure not less than 1.5 times the rating pressure at 38 degree C (rounded to the next
higher 1 bar increment), i.e. 29 Kg/cm2g as per BS 6755/MSS SP-61. For disk strength
test the side of disk to which pressure is applied shall be the direction in which the disk
is weaker.
• Seat & stem seal leakage Test: Seat testing shall be done only in one direction. The
manufacturer shall be able to demonstrate that the direction selected is at least likely to
attain effective tightness. The hydrostatic seat test pressure shall be the gage pressure
not less than 1.1 times the rating pressure at 38 degree C (rounded to the next higher 1
bar increment), i.e., 19 Kg/cm2g as per BS 6755/MSS SP-61.
• Pneumatic seat test pressure shall be carried out at a pressure of 5.6 Bar.
• For all the above tests, test procedure approved by the purchaser shall be followed.
The purchaser or their representative(s) shall witness all the tests.
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• Life tests: The supplier shall perform life test of valve for 25,000 cycles and again
checked for conformity with specifications and leak tests. Type test reports/certificates
shall be submitted to purchaser before dispatch.
8. Final Documentation:
i) After drawings are approved contractor shall furnish one (1) reproducible and five
(5) additional complete sets of finial drawings including all subsequent revisions
approved by the purchaser. The reproducible shall be of good quality capable of
producing clear legible prints.
ii) Final as built dimensioned assembly drawings of valve with mounted actuators,
solenoid valves duly piped.
iii) Torque Vs angle/travel curves for offered valves and for actuators.
iv) Actuators final make and model with dimensioned cross sectional drawing with bill
of material.
v) Solenoid valves final make and model with dimensioned cross sectional drawing
with bill of material.
vi) Relevant material test certificates with reports of chemical & physical properties for
all materials with identification for valves/ Actuators/ Solenoid valves.
vii) Inspection/testing certificates & reports for Butterfly valves/ Actuators/ Solenoid
valves.
viii) Operating and maintenance manual for Butterfly valves/ Actuators/ Solenoid valves.
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Annexure-I
6. Material of Construction:
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ANNEXURE-II
(Technical Datasheet)
(To be furnished along with offer)
i) Tender No. :
iv) Make :
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ii) Maximum output torque :
i) SV Make/ Type :
ii) Pressure rating :
iii) Insulation :
iv) Operating speed :
v) Coil current :
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TECHNICAL SPECIFICATIONS FOR BALL VALVES
1.0 SCOPE:
Design, Manufacture, Assembly, Inspection, Shop testing, packing, transport and
safe delivery and Guarantee of full bore three/two piece ball valves of size 25 NB
stainless steel construction flanged ends with companion flanges as per BS: 5351
of pressure rating ANSI class 150 lbs. lever operated and flanged ends conforming
to ANSI B 16.11/ANSI B.16.25/ANSI B 16.5 for end connections.
Fluid service: Air services Gas with Nitric acid vapors
2.0 DESIGN REQUIREMENTS:
The valve shall be designed as per BS: 5351. The valve shall be suitable for the
application mentioned above and shall stand at least over 5000 cycles for
temperature and applicable erosive and corrosive services. The above valves are
required for on/off service as well as throttling service. The valve shall be close to
full bore design, the design Cv = 43 for 25NB.
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4.0 MATERIALS AND WORKMANSHIP:
Materials and standard parts which are not specifically described herein and are
under the scope of supply of the bidder shall be of genuine quality and in
accordance with good practice pertinent to the manufacture of austenitic stainless
steel valves and shall also be subject to approval by the purchaser. All materials
shall conform to ASTM standards suitable for the service.
Materials subjected to welding shall be extra low carbon austenitic stainless steel.
The workmanship shall be of consistent high quality in accordance with the best
methods of manufacture, adequate to ensure satisfactory operation, service life and
ease of maintenance.
5.0 DESIGN/ MATERIAL OF CONSTRUCTION: ( VALVES )
5.1 The ball valve shall be cavity free, full bore two piece design and shall be designed
and stem shall be anti blow out type as per BS: 5351.
5.2 Ball valves specially, body and ball shall be made from investment casting.
5.3 Valve shall be of 2/3-piece design flanged end type for sizes up to 40mm NB.
5.4 The valves for above services communicate with toxic & corrosive (Nitric acid)
environment of feeding vessels fluids and vaporous and are likely to be
contaminated with the environment hence special care has to be taken for material
selection, construction and leak. tightness vis-à-vis seat leak and steam leak. All
material selected metallic/nonmetallic shall be suitable for nitric acid service.
5.5 All companion flanges for flanges ends shall be stainless steel 304L flanges and
shall be as pressure rating of ANSI class 150 and shall be as per ASTM A 180.
5.6 All metallic parts on valves including atmospheric seal parts, cover, nuts bolts etc.
shall be of stainless steel 304 grade, parts requiring weld joint shall be of stainless
steel 304L grade. The non-metallic parts shall be of PTFE/GRAFOIL/carbon filled
PTFE.
5.7 The body shall be of cast stainless steel construction, conforming to ASTM A 351
Gr. CF 8/8M for flanged and CF3/3M for butt welded ends and shall be free from
surface defects such as slug, blow holes, protraction etc. The minimum surface
finish shall be pickled and passivated. Alternatively better material for parts,
considering Nitric acid compatibility may be offered. Valves shall be 150 lbs
rating.
5.8 Stem shall be blow out proof. Ball shall be integral with stem and shall be made
out of AISI 304 Gr. Stainless steel. The surface shall be ground finish.
5.9 The ball/stems shall be ground finished with surface finish accuracy of less than
1.6 microns and sphericity of ball shall be less than 20 micron.
5.10 PTEF seat shall be firmly fitted in the body with the suitable provision for anti
rotation and expansion.
5.11 All mounting material used for actuator/ solenoid valve shall be SS 304/ SS316.
All fasteners used for mounting shall be SS 304/ SS316
5.12 The valves shall be delivered in clean, grease-free, oil-free and dirt-free condition
with both ends blocked with caps. The surface finish shall be as per the
specifications.
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5.13 The following data shall be indicated on the valve nameplate, which shall be of
stainless steel and fixed with SS screws.
i) Valve size, Identification No.
j) Pressure and temperature rating.
k) Body material, Seat/seal material.
l) Operating air supply pressure.
m) Direction of flow.
n) Two blank spaces for user identification of valve
5.14 The valve shall be suitable for on/off service.. The valve internals shall be smooth
and particularly designed for the withstanding erosion due to partial opening. The
degree of opening shall be in multiples of 10.
5.15 The stem sealing arrangement shall have adequate design provisions and long life
of high degree of leak tightness and shall be suitable for easy replacement. It shall
be emphasized that the seal leak tightness is of primary importance for these
applications. Design should be fire safe with grafoil packing at top cap to reduce
atmosphere leakage to a negligible. Multiple seal arrangement shall be preferred.
5.16 Manually operated valves shall be provided with Stainless steel lever & fixing hub
arrangement.
6.0 INSPECTION AND TESTING:
The supplier shall be responsible for and shall provide and perform all the
inspection and testing required to insure material, workmanship and operations are
of a degree of excellence as required by this specification. The valve shall be
checked for conformity with all specifications mentioned above. In addition the
following tests are also done.
6.1 The supplier shall notify the purchaser the date and location for the tests, giving
sufficient time to enable the purchaser or his authorized representative to be
present. The supplier shall provide all the test equipment required
6.2 The manufacturer for the valve parts shall carry out physical and chemical analysis
and test certificates shall be furnished to the purchaser.
6.3 All cast/forged components of valves shall be Dye Penetrant tested for surface
flaws as per the specifications after machining.
6.4 The balls of the valves shall be checked for dimensional accuracy and spherical
and surface finish
6.5 Material confirmation and/or corrosion tests shall be performed on a few valves,
picked at random, as are deemed necessary by the purchaser to test suitability for
nitric acid service by dipping the full valves in 40% nitric acid for one hour.
Valves shall then be stripped to check any sign of corrosion and tested for leak
tightness. The supplier shall provide all the facilities.
6.6 All valves bodies shall be hydro pressures tested as per SP-61/BS-6755 to 29.8
Kg./cm2g shell hydro. Seat as well as stem leak tightness shall be tested for 19.3
Kg./cm2g hydraulic. There shall be no leakage past stem seal. Maximum
permissible seat leakage shall be 5cc/hr./inch of dia. of nominal size for hydraulic.
For pneumatic leakage test at 5.6Kg./ cm2g maximum permissible leakage in each
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valve shall be 1/10 of standard.ft3. of air per hr. per inch of dia. of nominal valve
size.
6.7 The Endurance test for 5000 ON/OFF cycles shall be demonstrated for two valves
of each size, picked at random from a lot of 100 valves. The valves shall retain its
seat and stem leak tightness all through the endurance test. In case of one of the
above two valves reaching successful 5000 cycles and other reaching at least 2500
successful cycles, the lot represented shall be acceptable. In case of failure another
four valves picked at random shall be tested, out of which, for acceptance at least
two valves shall reach 5000 cycles successfully. All the valves that are put to life
cycle test shall be replaced with new valves at the manufacture account.
7.0 DRAWINGS / DOCUMENTS AFTER AWARD OF CONTRACT:
Three sets of the following documents shall be submitted for purchaser’s approval
before start of manufacture within 30 days of purchase order issue.
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ANNEXURE -I
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3.4 Seat ring and its profile :
3.5 ‘O’-ring and nos. on shaft seal :
3.6 Bearing :
3.7 Pin :
3.8 Handle :
4 HYDROSTATIC TEST DATA FOR BALL VALVE
4.1 Max. hydrostatic pressure for :
shell/body
4.2 Seat leakage test pressure :
4.3 Stem leakage test pressure :
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