ARAMCO-Valve Inspection and Testing Requirements%20.pdf

Jubail Export Refinery Material Specifications

JERMS-L-4048 Valve Inspection and Testing Requirements

Revision

Responsibility

28 April

0

JER Engineering

2008

Jubail Export Refinery Material Specifications JERMS-L-4048 Rev. 0

Valve Inspection and Testing Requirements

28 April 2008

Revision Tracking Revision

Revision Date

Scope of Revision

0

28 April 2008

Issued for bid package.

02

31 March 2008

Issued for bid package only for review.

01

27 July 2007

The first official JERMS-L-4048 JERMS-L-4048 is issued.

26 February 2007

First draft issued is b ased on Saudi Aramco 04-SAMSS-048“Valve 04-SAMSS-048“Valve Inspection and Testing Requirements” issue date 21 December, 2005. Document was modified to incorporate amendments and modifications.

00

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by



28 April 2008

Table of Contents Section

Contents

Page

1

Scope

4

2

Conflicts, Deviations and Clarifications

4

3

References

5

4

Definitions

6

5

General Requirements

7

6

Pressure Tests

7

7

Hardness Testing

8

8

Impact Testing

8

9

Inspection and Testing of Castings

8

10

Plating Tests

9

11

Sampling Criteria

10

12

Documentation Requirements

10




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1

Scope

1.1

This Specification, together with the Purchase Order and appropriate data sheets, cover the minimum requirements for inspection and testing of metallic and nonmetallic valves. Such valves include gate, globe, angle, check, needle, ball, plug, piston, butterfly, choke, diaphragm, etc., used for on-off, manual control service or for prevention of reverse flow, as appropriate.

1.2

Specifically excluded from the scope are: control, safety-relief, relief, surge relief, solenoid, pilot and other valves classified instrumentation valves.

1.3

Exception: API STD 6A 6A 10,000 psi psi (1-13/16 inch size and and above) valves and chokes are are exempted from this specification.

1.4

The typical quality characteristics to be witnessed and the documents to be reviewed by and/or provided to Company Representative by the Vendor, are specified on Company Inspection Requirements JERITP-L-043000 JERITP-L-043000,, JERITP-L-043600 JERITP-L-043600 and and JERITP-L-043601 which JERITP-L-043601 which shall be included as part of the Purchase Order, as applicable.

2

Conflicts, Deviations and Clarifications

2.1

Any conflicts between this standard and other applicable Company Engineering Standards (JERES), Material Specifications (JERMS), Standard Drawings (JERSD), Engineering Procedures (JEREP), Company Forms or Industry standards, specifications, Codes and forms shall be brought to the attention of Company Representative by the Contractor for resolution. Until the resolution is officially made by the Company Representative, the most stringent requirement shall govern.

2.2

Where a licensor specification is more stringent than those of this standard, the Licensor’s specific requirement shall apply.

2.3

Where applicable Codes or Standards are not called by this standard or its requirements are not clear, it shall be brought to attention of Company Representative by Contractor for resolution.




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2.4

Direct all requests for deviations or clarifications in writing to the Company or its Representative who shall follow internal Company procedure and provide final resolution.

3

References The selection of material and equipment, and the design, construction, maintenance, and repair of equipment and facilities covered by this standard shall comply with the latest edition of the references listed below as of the CUT-OFF DATE as specified in the Contract unless otherwise noted.

3.1

Company References Company Materials Specification JERMS-L-4003 JERMS-L4003

Additional Requirements for Low Temperature Valves

Company Inspection and Testing Requirements JERITP-L-043000 JERITP-L -043000

Valve Materials Certification Requirements

JERITP-L-043600 JERITP-L -043600

Valves: Metallic; includes gate, globe, angle, check, needle, ball, plug, piston, butterfly and choke; Excludes Control, Safety-Relief

JERITP-L-043601 JERITP-L -043601

Valve: Low severity, Utility Service in Cast Iron, Brass Material and Butterfly Valves Valves

Note: Please check the above form form numbers and make sure sure they are correct.

3.2

Industry Codes and Standards American Petroleum Institute API STD 598 598

Valve Inspection Inspection and Testing

American Society of Mechanical Engineers ASME B16.34 B16.34

Valves-Flanged, Valves-Flanged, Threaded, Threaded, and and Welding End End

ASME SEC VIII

Boiler & Pressure Pressure Vessel Vessel Code Code

American Society for Testing and Materials ASTM A956

Standard Test Method Method for Leeb Hardness Hardness Testing Testing of Steel Steel Products




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ASTM B733

Standard Specification Specification for Autocatalyti Autocatalyticc Nickel-Phosphoru Nickel-Phosphoruss Coatings on Metals

ASTM E10

Test Method Method for Brinnell Brinnell Hardness Hardness of Metallic Metallic Materials

ASTM E18

Test Methods Methods for Rockwell Rockwell Hardness Hardness and Rockwell Rockwell Superficial Superficial Hardness of of Metallic Materials Materials

German Standards DIN EN 10204 10204

Metallic Materials Materials

Manufacturers Standardization Society MSS SP-53

Quality Standard Standard for Steel Castings Castings - Magnetic Magnetic Particle Particle Examination Examination Method

MSS SP-54

Quality Standard Standard for Steel Castings Castings - Radiographic Radiographic Inspection Inspection Method

MSS SP-55

Quality Standard Standard for for Steel Castings Castings - Visual Visual Method

MSS SP-93

Quality Standard Standard for for Steel Castings Castings - Liquid Liquid Penetrant Penetrant Examination Examination Method

4

Definitions

4.1

Definitions presented in this Standard and other JER documents have precedence over other definitions. Conflicts between various definitions definitions shall be brought to the attention of Company Representative by the Contractor for resolution. Company: Jubail Export Refinery.

from the Company or an assigned Company Representative: A designated person from third party representative. Company Inspector: A designated person or an agency responsible for conducting inspection activities on behalf of the Company.

4.2

List of Definitions Purposely left blank.




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5

General Requirements

5.1

Each individual valve shall be at least tested, examined and qualified as specified in the industrial standard (such as ASME, API, AWWA, MSS) referenced in the Purchase Order or to the manufacturer's approved standard if no industrial standard has been specified. Nothing in this Specification shall be construed as waiving any mandatory requirement of the referenced Standard. Steel valves shall not be painted or externally coated before the shell pressure tests are completed. Internally epoxy coated or internally lined lined steel valves shall be shell tested before and after application of the coating or lining unless specified otherwise by the Company Representative.

5.2

Repairs of valve components with unacceptable defects shall be in accordance with the governing material specification for the the component. Proposed weld repairs that are not covered by the applicable material specification shall require the approval of Company's Engineer prior to the performance of repair work. All pressure tests shall be repeated on valves after any weld repair to the pressure retaining components. Repair by grinding or redressing of the casting surface is acceptable, provided that during the repair not more than 10% of the original wall thickness will be removed and provided that the minimum required wall thickness is not affected, the weld repair documentation shall be submitted to Company Representative.

5.3

When valve installation orientation is specified in the Purchase Order, applicable tests shall be conducted with the valve in the specified position.

6

Pressure Tests

6.1

When there is an industrial standard referenced in the Purchase Order, valves shall be tested to the requirements of that standard (e.g., ASME, API, MSS, AWWA, etc.). In addition to tests per the applicable standard, the testing requirements in the following paragraphs shall apply for steel valves:

6.1.1

For all cast steel valves NPS 2 and below, the shell hydrostatic test shall be maintained for one minute. For all other sizes, the shell test pressure shall be maintained for a minimum of five minutes or as requ ired by the applicable industry standard, whichever is greater.

6.1.2

When specified in the Purchase Order, steel valves shall be subjected to a pneumatic high-pressure shell test test per API STD 598 paragraph 3.5. The holding time shall be a minimum of 5 minutes and no visible leakage is allowed.




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6.1.3

Valves specified for flare system isolation service, regardless of size, shall receive low pressure pneumatic seat tests at 5 psig.

6.2

When there is a governing industrial standard, but it does not specify test durations or leakage acceptance criteria, paragraph 5.1.1 and API STD 598 requirements for durations and leakage shall apply, unless specified otherwise by the Company Representative.

6.3

When there is no referenced governing industrial standard, valve testing shall be in accordance with the following requirements:

6.3.1

Metallic valves NPS 2 and smaller, and all non-metallic valves, shall be tested per Vendor's procedure as approved by the Company Representative.

6.3.2

Metallic valves larger than NPS 2, shall be tested in accordance with paragraph 5.1.1 and API STD 598 requirements for shell tests and closure tests, unless specified otherwise by the Company Representative.

6.4

When a valve is ordered together with an actuator, the valve/actuator assembly shall be tested together as a unit. As part of functional testing, the valve shall be opened under the maximum differential pressure pressure that the actuator has been rated for. The vendor shall take necessary steps to ensure e nsure that the valve is not damaged d amaged during this functional test.

7

Hardness Hardn ess Testing Hardness tests, when required by specified service and/or material specification, shall be conducted by the Vendor on all wetted parts in accordance with ASTM E10, ASTM E18 or ASTM E956 Leeb hardness test.

8

Impact Impac t Testing estin g When JERMS-L-4003 JERMS-L-4003 is is specified in the Purchase Order, the Vendor shall conduct impact tests as required by the Specification.

9

Inspection and Testing of Castings

9.1

Visual Inspection All castings shall be visually inspected in accordance with MSS MSS SP-55. A casting shall be rejected if any surface irregularity exceeds e xample "a" of any defect type as per MSS SP-55.



9.2


28 April 2008

Surface Examination For cast steel valves NPS 3 and larger, the internal and external surface areas of 10% (minimum one) of all pressure retaining steel castings (bodies, bonnets, cove rs) per heat shall be magnetic particle or liquid penetrant inspected in accordance with MSS SP-53 or MSS SP-93. If any unacceptable defect is detected, all castings from that heat shall be inspected.

8.3

QA Program Casting qualification and Volumetric Examination

9.3.1

As part of their QA program, the Vendor shall implement a qualification procedure for all pressure containing steel steel castings. As a minimum, the vendor shall have qualified each foundry's casting patterns by radiographic examination of the initial casting. Records of these qualifications shall be made available upon request.

9.3.2

In addition to 8.3.1, for cast steel valves (a) NPS 4 and larger in ASME Class 600 (or API STD 6A rating 2000 psi) and higher and (b) NPS 24 and larger in all ratings, radiography shall be performed performed in accordance with 8.3.3. The examination shall be in accordance with and have included all critical areas as defined in ASME B16.34, paragraph 8.3.1.1. For valves other than those included in ASME B16.34 figures, ASME SEC VIII , app. 7, section 7.3(a).1 Footnote 1 shall be used to determine the critical areas. See paragraph 8.3.4 for valves that are exempt.

9.3.3

The Vendor shall radiographically examine and qualify one valve per size per heat from the lot on order. If this radiographic sampling sampling results in a rejection rejection (defined as requiring weld repair) then an additional 10% sample from the same size and foundry shall be subjected to radiographic examination as defined in 8.3.2. Further radiographic rejects resulting from this inspection mandates 100% Radiography of castings as defined in 8.3.2.

9.4

Valves fabricated by welding shall be qualified in accordance with ASME B16.34, paragraph 2.1.5.

10

Plating Platin g Tests The Vendor's Quality Assurance program shall include the following tests of carbon and low alloy steel electroless nickel plated parts on a sample basis:

10.1

Bend Test per ASTM B733 paragraph 9.4.1. There shall be no evidence of lifting upon insertion of a sharp probe at any ENP-Base Metal interface.



10.2


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Ferroxyl Test per ASTM B733 paragraph 9.6.1. There shall be no indications in primary service exposure areas. When this test is impractical due to the size of the parts, the Vendor shall submit an alternate procedure for approval by the Company Representative.

11

Sampling Criteria Visual inspection and witnessing shall be based on Table 1 sampling sampling plan. At minimum, the sample shall include at least one valve from each Purchase Order item. The sampling plan does not relieve the Vendor of the responsibility to ensure compliance of each valve with specified requirements and to test each valve. When a discrepancy is found, the entire entire lot shall be rejected. rejected. The lot shall be re-inspected and re-tested by the Vendor, p rior to presenting them again for inspection. Table 1 Valve Category

Minimum Sample Size (% of Item Quantity)

All valves NPS 2 and smaller all ratings

10%

2< valves < 14 NPS and less than ASME Class 600

25%

All valves NPS 14 and above All valves >2" and ANSI Class 600 and above All valves >2" and API rating 2000 psi and above

100%

However, if Company's Representative witnesses a failure of a hydrostatic shell test, all valves in the lot shall be re-tested and witnessed by Company's Representative. The cause of failure shall be investigated and reported.

12

Documentation Requirements

12.1

Material Test Reports and Certificates shall be supplied in accordance with Company Inspection Requirements JERITP-L-043000.

12.2

All certificates and test reports shall identify the valve(s) by stating Purchase Order and Item number, Vendor's name, type, size and rating of valves, and quantity of valves covered.



12.3


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Certificates of castings shall include weld repair data including extent of repair, WPS, welder qualifications, post weld heat treatment and NDE following the repair(s).


ARAMCO-Valve Inspection and Testing Requirements%20.pdf

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