HINDUSTAN PETROLEUM CORPORATION

LTD. (A Government of India Enterprise)

RKPL PROJECT (FOR TERMINALS)

BID DOCUMENT

FOR

Supply of ROSOV

PUBLIC INTERNATIONAL COMPETITIVE BIDDING

VOLUME – II of II

BID DOCUMENT NO. 13000121-HD-10129

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SPECIFICATIONS FOR REMOTE OPERATED SHUTOFF VALVES (ROSOV)

TRIPLE OFFSET, DOUBLE FLANGED ,

BUTTERFLY VALVES WITH FAIL SAFE ELECTRO HYDRAULIC AND

PNEUMATIC ACTUATORS

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List of Content 1 Introduction 1.1 Definitions 2 Applicable Codes, Specifications and Standards

2.1 General 2.2 Deviations to Specification 2.3 Conflicting Requirements 2.4 Abbreviations &Terminology

3 Product Details Plant Environmental Conditions 4 Hazardous Area Classification and Protection 5 Utilities Specification 6 Scope of Supply 7 Specifications & Documents attached 8 Technical

8.1 Design & Construction 8.2 Materials &Test Procedures

9 Pneumatic Actuators for Shutdown Application 9.1 General 9.2 Accessories (all actuators) 9.3 ROSOV Operation

10.0 Inspection and Tests 10.1 General 10.2 Actuator 10.3 Test Certificates

11.0 Spares &Accessories 12 Documentation Guarantee 14.0 Site Service/Site Visits by Experts.

15.0 Painting, Marking and Shipment// Storage DATA Sheets- Valve, Actuator, Solenoid Valve

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1 Introduction Hindustan Petroleum Corporation Limited (HPCL) proposes to procure Remote Operated Shut Off Valve (failsafe) with electro hydraulic actuators for Bharatpur location and ROSOV with pneumatic actuator for Mathura location. The purpose of this specification is to define the requirements for pneumatic actuated on/off shut down valves for the following services- • Tank Overfill Protection Shutdown via Emergency Shutdown System with use of (ROSOVs) pneumatically remotely operated valves from ESD (SIS) System. Overfill protection system shall be de-energized to trip. Solenoid Valve of ROSOV shall be SIL2 Certified and operate on 230V AC. This specification covers the minimum requirements for the design, manufacture, assembly, Inspection, testing, certification & delivery of On-Off type Triple Offset Butterfly Valves with Electro hydraulic and Pneumatically operated actuator complete with all accessories, for HPCL Bharatpur and Mathura Locations as per following.

Group Location Item no Descrption Unit Qty

A Bharatpur

A1 Supply of 12 inch ROSOV with Electrohydraulic actuator Each 1

A2 Supply of 10 inch ROSOV with Electrohydraulic actuator Each 9

A3 Supply of 8 inch ROSOV with Electrohydraulic actuator Each 16

A4 Supply of 6 inch ROSOV with Electrohydraulic actuator Each 4

B Mathura B1 Supply of 18 inch ROSOV with Pneumatic actuator Each 2

1.1 Definitions Owner : Hindustan Petroleum Corporation Ltd Bidder / Manufacturer Valve Manufacturer Engineer In- charge Means the Resident Engineer or a person acting on behalf of

HPCL at site

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Shall : This is to be understood as a mandatory in relation to the requirements of this Document. Should : This is to be understood as a strong recommendation to comply

with the requirements of this document. 2 Applicable Codes, Specifications and Standards 2.1 General

2.1.1 The items shall be designed and supplied in accordance with this Specification and the codes

and standards referenced herein. The design, manufacture, assembly, inspection, testing and

certification of Pneumatic Operated on off type triple offset high performance butterfly valves

shall be in accordance with the latest edition of the codes including amendments, specifications and

standards (including standards / specifications mentioned therein )listed in this requisition.

API598 2004 Valve Inspection and Testing

API-6FA 1999 Specification for Fire test for Valves.

API607 2005 Fire test for soft-seated quarter-turn valves

API609 2009 Butterfly Valve Design

ASMEB1.20.1 1983 Pipe Threads, General Purpose(inch)

ASMEB16.5 2003 Steel Pipe Flanges and Flanged Fittings

ASMEB16.10 2000 Face-to-Face and End-to-End Dimensions of Valves

ASMEB16.34 2004 Valves–Flanged, Threaded, and Welding End

ASMEB31.3 2004 Chemical Plant and Petroleum Refinery Piping

ASMEB31.4 2004 Liquid transportation systems for hydrocarbons and other liquids

ANSIB46.1 1995 Surface Texture(Surface Roughness, Waviness & Lay)

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BSEN12266 Part2

2002 Industrial Valves, Testing of valves, test procedures & Acceptance criteria.

EN50018 2000 Electrical Apparatus for Potentially Explosive Atmosphere [EEx(d)]

IEC60079 2006 Electrical apparatus to explosive gas atmosphere.

IEC60529

2004 Classification of degrees of protection provided by Enclosures (IPcodes).

IEC60801 1991 Electromagnetic compatibility of Industrial-Process management and control equipment

IEC61508 Functional

2010 Safety of Electrical/Electronic/ Programmable Electronic Safety Related Systems

IEC61511 2010 Functional safety–Safety Instrumented Systems for the Process Industry Sector

MSS-SP-61 2003 Pressure Testing of Steel Valves

SSPC-VIS-1 2002 Steel structures painting council-visual standard

IS-2148 2004 Flame-proof enclosures for electric apparatus, etc:

IS-1271 1985 Methods for determining thermal classification of electric insulation.

2.2 Deviations to Specification 2.2.1 The Bidder shall provide an itemized list of any deviations to this specification. These shall be listed on the Compliance sheet with seal & duly signed by authorized signatory & shall be submitted along with offer by the Bidder. 2.2.2 Where conflict between standards occurs then the Bidder shall seek a clarification ruling from the Owner. Where a deviation from the standard is required, then the Bidder shall make formal request with full supporting information. 2.2.3 Only those deviations that are agreed between the Owner and the Bidder will be incorporated in to the requisition at the time of order. 2.3 Conflicting Requirements

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In case of conflict between the requirements of this specification, API609 and the Codes, Standards and Specifications referred in clause 2.1 above, the requirements of this specification shall govern. Order of precedence shall be as follows: First priority - Data Sheets Second priority - This Specification Third priority - API 607 609 Fourth priority - Other Referred Codes &Standards Fifth priority - Manufacturer‟s Standard Note: Should any conflict arise either before or after order placement the Bidder shall immediately inform the Owner for technical resolution of the conflict

2.4

Abbreviations &Terminology

CE Carbon Equivalent

DVC Digital Valve Controller

ESDV Emergency Shutdown

valve FAT Factory Acceptance Test

FB Full Bore

FC Fail Safe Close

FMEDA Failure Modes Effects and Diagnostic

Analysis. FO Fail Safe Open

GUI Graphical User Interface

HFT Hardware Fault Tolerance MOV Motor Operated/ Actuated On-Off Valve IEC International Electro-technical Commission IS Intrinsic Safety ISA Instruments Society of America JB Junction Box LO Lock Open/ Full Open LC Lock Close/ Full Close LSS

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Long Standing Still MOS Manual Override Switch MOV Motor Operated Valves MSBT Maximum Spring Break Torque MTBF Mean Time Between Failures MTTR Mean Time To Repair PFD Probability of Failure on Demand PST Partial Stroke Testing PSTD Partial Stroke Testing Device QAP Quality assurance Plan RC Regular Cycling ROSOV Remote Operated–ESDV SAT Site Acceptance Test SFF Safe Failure Fraction SET Spring End Torque SIL Safety Integrity Level SIS Safety Integrated Systems SOV Solenoid Operated Valve SRT Spring Return Torque SST Spring Standing Torque TAS Terminal Automation System TFMS Tank Farm Management System TOBV Triple Offset High Performance Butterfly Valves. VAC Volts alternating current VDC Volts direct current CCOE Chief Controller Of Explosives CMRI Central Mining Research Institute 3 White Oil product details In the table below, Product Characteristics of the products are mentioned as general guidelines to bidders

Product

Flash point (OC)

Specific gravity gm/cc

Vapour pressure kg/cm2a

Viscosity (cSt)

Pumping Temp. (OC)

HSD - High Speed

> 35

0.82-0.86

< 0.4

2-5 @ 40OC

Ambient

Diesel MS -

(-) 30

0.73

0.7

< 0.7

Ambient

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Motor Spirit Naphtha

(-) 20

0.69- 0.78

< 0.7

< 0.7

Ambient

ATF -

> 35

0.8

< 0.4

2.56

Ambient

Aviation Turbine Fuel

101

Ambient

SKO - Super Kerosene Oil

> 35

0.8

< 0.05

1.97

Ambient

MTO - Mineral Turpentine Oil

33

0.82

0.01

14.92

Ambient

Hexane

(-) 23.3

0.66

0.37 0.277 Ambient

Ethanol 16.6 0.79

0.08

1.2

Ambient

The above product specifications are indicative and may vary. 4 Hazardous Area Classification and Protection 4.1 Instruments located in hazardous area shall be certified to meet or exceed the electrical hazardous area defined by Area classification 4.2 The actuator accessories used shall be flame proof and suitable for hazardous area of Zone1,Group IIA/IIB,T3 or better for applications. Additionally all valve associated instruments shall be weather proof to IP65 as minimum. Instruments certified for use in the specified hazardous area classification shall have certifications/ approvals from accredited international agencies like FM, ENELEC, PTB, BASSEFA, ATEX, etc.

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All enclosures for electrical equipment shall be suitable for use in Hazardous are as per Haz. Area Classification and vendor shall submit valid test certificate issued by CIMFR & PESO. Flameproof enclosures and instruments which are manufactures outside India and certified by accredited international authorities shall also have approval of PESO, India. 5 Utilities Specification 5.1 Instrument Air Supply pressure may range between 4.5kg/cm²(g) to 6.5kg/cm²(g). However Actuator shall be sized for instrument air supply pressure of 4.0kg/cm2 (g) & shall withstand the design pressure 10kg/cm2(g). 5.2 Electric Supply of 230 V (+/- 10%) AC, 50 HZ (+/- 5%) 6 Scope of Supply 6.1 The scope of this tender covers the design, manufacture, testing and supply of electro hydraulic and pneumatically actuated, failsafe to close valves to be installed on the tank body of petroleum storage tanks as per the specifications and data sheets attached. These valves are part of SIS for tank overfill protection & functioning as ROSOVs(ESDVs). Complete actuated valve assembly shall have capability for use in SIL 3 application having certification from TUV / Exida as per IEC 61508. However the designed SIS loop has one ROSOV & as per IEC 61508, the architectural constraint limits overall loop SI to SIL2. 6.2 This specification covers the minimum requirements for design, manufacture and supply of fire safe, triple offset ,metal to metal seated, high performance, bidirectional- zero leak tight shutoff, non-rubbing, torque seated, antistatic, anti-blow out stem arrangement, quarter turn, double flange end butterfly valves of size equal& more than DN 100 mm (4") to DN 700 mm (28”) as a complete assembly of valve & actuator unit with all accessories. 6.3 The materials, design and workmanship shall satisfy the relevant standards, specifications & codes referred in this document. Where the specifications stipulate requirements in addition to those contained in the standard, codes and specifications, these additional requirements shall also be satisfied. 6.4 The Bidder shall supply the complete assembled and tested valve with actuator & related accessories. The designed, engineered and supplied equipment/ system shall be suitable for the site conditions specified. All components/consumables used shall be new, state of the art and of current manufacture. 6.5 Bidder shall include in the bid, list of specific deviations, separately, if any, to this specification and all attachment thereof, otherwise, the offer will be deemed to be in compliance with complete tender and its attachments and subsequent claims for extra scope will not be considered.

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6.6 This specification does not relieve the Bidder from final guarantee as to materials, apparatus, workmanship and performance of the valve supplied. 6.7 The Bidder shall, in respect of this tender, procure material from approved makes/vendors listed in the datasheet notes, unless the particular type of material is not covered by the list, or a special dispensation to deviate from the list has been granted in writing by the Owner.

6.8 Vendor / Bidder to include the startup & commissioning spares for valves, actuators and other

accessories in the quoted price and the list of such spares shall be provided in the technical bid.

6.9 Deleted. 6.10 Approved vendor/ makes are provided in this tender is for the manufacturer name only, and not for any specific model. For all items/components the offered model must meet the relevant specification and proven track record (PTR) requirements as specified in this tender document. The Bidder shall provide the related necessary evidence for use of their valves in similar application (reference lists with installation dates and run hours accumulated by date, etc.). Only equipment of proven reliability in similar service conditions, shall be included in the Bidder‟s proposal (prototypes shall not be proposed). 6.11 Bidder shall prepare and submit all necessary documents during various stages of the project as listed in this tender document. 6.12 Inspection and testing of all components, sub-assemblies and complete assemblies of items manufactured at Bidder‟s works, and other sub-Vendor‟s/Supplier‟s Bidder‟s works shall be in accordance with approved QA/QC procedure. 6.13 Factory Acceptance Test (FAT) shall be performed in line with tender requirements & as per approved post PO FAT procedure . Providing necessary manpower & equipment support during FAT/ testing is in bidder‟s scope. Specifications & Documents attached

7.1 Specification, datasheets, schedule of quantities for valves are appended to the specification.

Technical 8.1 Design & Construction of Triple Offset High Performance Butter fly Valves 8.1.1. Metal seated butterfly valve shall be supplied with anti-static devices.

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8.1.2. Butterfly valves shall be as per API 609 with double flange ends construction. Dimensions shall be as per API 609 long pattern. 8.1.3. Flanged end shall have dimensions as per ASME B16.5 . 8.1.4. Flange face shall be raised face. Flange face finish shall be serrated or smooth as indicated in Valve Data Sheet. Smooth finish when specified shall be 63-125AARH smooth finish. 8.1.5. When specified in the valve data sheet, valves shall be designed to withstand a sustained internal one milli bar vacuum in both open and closed position. 8.1.6. Valves shall be provided with position indicator and stops at the fully open and fully closed positions. 8.1.7 Manufacture unit shall be in possession of valid ISO 9001 certificate 8.1.8 Valve should meet ISO 15848 standard for fugitive emissions 8.1.9 Vendor will indicate closing torque required for each size of the valve for their closing. Valve will be pressure tested at closing torque and should achieve zero leak . 8.1.10 Valve shall be manufactured with close tolerance and should employ robotic welding and 3D measurement of seat and disc . 8.1.11 Valve body to be in single piece and valve seat disc should not protrude out side the valve body upto 20” size. 8.1.12. Valves of size DN 200 mm (8”) and above shall be equipped with lifting lugs. Tapped holes and eye bolts shall not be used for lifting lugs. Incase lifting lugs are not provided on the valve then vendor shall provide detailed instruction set for handling the valves for installation without need of lifting lugs. 8.1.13 Valves shall be of fire safe design as per BS EN 12266 Part2 /API6FA/ API607,as indicated in Valve Data Sheet. As a special requirement one valve for each size selected randomly by TPI shall be fire tested as per the specifications at the manufacturers place over and above the requirements specified in the API standards. 8.1.14 Valves shall be suitable for above ground installation as indicated in the Valve Data Sheet. 8.2 Materials & Test Procedures

8.2.1 Material for major components of the valves shall be as indicated in Valve Data Sheet.

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

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8.2.3 The Carbon Equivalent (CE)of valve end connections, shall not exceed 0.45% (as calculated by the following formula) on check analysis for each heat of steel used:

8.2.4 Charpy V – Notch test on each heat of base material shall be conducted as per API609, for all pressure containing parts such as body, end flanges and welding ends as well as bolting material for pressure containing parts. Unless specified otherwise, the Charpy impact test shall be conducted at 0°C. The Charpy impact test specimen shall be taken in the direction of principal grain flow and notched perpendicular to the original surface of plate or forging. 8.2.5 The minimum average absorbed energy per set of three specimens shall be 27J with an individual minimum per specimen of 22J. No specimen shall exhibit less than 80 per cent shear area. 8.2.6 The hardness of base material of body and principal parts of the valve such as disc & body etc. shall not exceed 22RC. Shaft/ Stem can be with higher hardness based on the shaft material & applicable relevant standard. 9 Pneumatic Actuators for Shutdown Application 9.1 General 9.1.1 Single acting–spring return pneumatic piston actuators of scotch & yoke type as specified in data sheet shall be used for shutdown services and where the valve design dictates. Rack & Pinion & Pressure balance actuators shall not be used. 9.1.2 These ROSOVs shall be equipped with spring return single acting piston actuators. 9.1.3 The required position of the valve when the controlling medium is lost shall be “Fail Closed” as indicated on the datasheets. 9.1.4 The actuator shall be sized using a factor of 1.25times the maximum shut-in head pressure to ensure that the actuator has sufficient built-in power to operate the valve from a closed in system or to ensure seating against such a condition. 9.1.5 The actuator-valve stem connection shall be a bolt-threaded split clamp. 9.1.6 Piston actuators shall be sized to provide the required force at supply pressure of 4.0

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kg/cm²(g) but must be suitable for pressures up to 10.0kg/cm²(g).

9.1.7 Where requested on data sheet the actuator shall be supplemented with air capacity tanks (with non-return valves, pressure gauges, drains etc.). Air capacity tanks shall be sized to provide adequate air storage such that three valve operations may be obtained between 4.0 and 6.5 kg/cm². The tanks shall be manufactured from carbon steel, painted and shall be to the pressure vessel code applicable to the project. 9.1.8 All tubing shall be 316 Stainless Steel and in imperial sizes. Permissible OD/ wall thickness shall be as follows: • ½"ODx0.049"wallthickness 9.1.9 Actuator colors shall be: RAL3001 Signal Red for Fail Close ROSOVs. 9.1.10 These ROSOVs will be used as tank body ( inlet/outlet) isolation with shutdown application for tank overfills protection. Bidder shall have the ROSOVs‟ with actuator installed in 90Deg. angle with nozzle/ pipeline axis. 9.2 Accessories 9.2.1 Accessories such as solenoid valves, AFRs etc., shall be procured and mounted by Bidder‟s Local Station in a field mounted cabinet. External tubing connection shall be either ½"O.D. Instruments shall be tropicalized for humidity and fungus and shall be termite resistant, IP65 classification. Bidder shall be completely responsible for the Functioning of the control scheme as per data sheet requirements. 9.2.2. Solenoid valves shall be certified EEx„d„ (except when data sheet calls for EEx‟i‟) coil rating 230V AC. Integral terminals shall be provided for the termination of cabling. Flying leads from the coil enclosure shall not be used. Pneumatic solenoid valves shall be constructed of stainless steel body, stainless steel trim and SS enclosure. Zero copper aluminium enclosures with two pack epoxy finish are acceptable. 9.2.3. The pneumatic actuator shall be fitted with micro switches as limit switches, one at the “open” and one at the “closed” position. The switches shall operate at less than 5% of the valve travel from their respective limits. 9.2.4. Limit Switches should be EEx„d‟. Bidder shall supply full technical specification of the switches in his offer. Switches shall be pre-cabled to a junction box mounted on the actuator using ½”NPT metallic glands. 9.2.5. Junction boxes shall be made from stainless steel, environmentally rated IP65 and certified EEx„d‟ for use in Zone1 hazardous areas as standard. Cables shall be clearly identified at both ends using securely fitted PVC cable markers. All cable cores and wiring shall be fitted with core identification ferrules at each end. All cores shall be terminated in terminals.

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9.2.6 All tube bending shall be carried out cold by gradually applied pressure using an approved type bending machine. Bending shall not include hammering or the application of any force which may damage the tube. Tube cutting shall be executed using an approved type tube cutter, saw cuts are not to be made. After cutting the ends shall be dressed with the appropriate belling tool to ensure that a restriction has not been introduced. Prior to installation, the tubing shall be internally cleaned, degreased with a suitable solvent and then dried.

9.2.7. All actuators/ valves shall be fitted with a permanently attached stainless steel labels (not wired-on) showing as a minimum the following information: • Bidder‟s name & OEM name • Model & serial numbers • Instrument tag number • Manufacturer‟s standard data • Position on actuation medium failure • Materials of construction of valve body • Pressure and temperature ratings(valve only) 9.2.8. Fireproofing of actuator is not envisaged. 9.2.9. All accessories mounted on valve assemblies shall be capable of withstanding line vibrations & surge. 9.3 ROSOV Operation 9.3.1. ROSOVs are part of SIS which consists of SIL3 ESD Safety PLC, SIL2 capable High Level Switch/ any other input element & ROSOVs as final control element. 9.3.2. Each ROSOV shall be with Emergency Close (Shut-off) Local Station which shall be located outside the dyke which is 20mtrs minimum from the ROSOVs. 9.3.3. Emergency Shut-off Local Station shall be made from LM-6 & having valid CCOE approval. Controls shall be mounted on front & shall be protected against inadvertent operation. 9.3.4. ROSOV Operation will be as follows:-

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a. The valve can be closed from the Local Station for Close Control. No mechanical manual overrides , lock out devices or by-passes are permitted. b. In addition to SIS functionality, the ROSOV can be closed from the control room either from ESD push button or through all operator interface stations for Operator‟s interaction with ESD safety PLC system(SIS) via the Graphical User Interface(GUI) facilities of the Terminal Automation System, wherever provided, with access control & security levels defined. c. A dedicated ESD graphics screens showing the status of each SIS connected equipment shall be developed by Terminal Automation System (TAS) vendor.

9.3.5. To reset , the system must be reset from the Emergency Reset station in control room or through TAS Operator Interface

10.0 Inspection and Tests 10.1 General 10.1.1 The Manufacturer shall perform all inspection and tests as per the requirements of this specification and the relevant codes, prior to shipment, at his works. Such inspection and tests shall be, but not limited to the following: 10.1.2 All valves shall be visually inspected. Dimensional check on all valves shall be carried out as per the Owner approved drawings. Owner shall have the right to inspect/witness the tests. 10.1.3 An indicative QAP has been furnished in the tender document. The bidder shall develop further this QAP based upon the specifications in the tender & submit the same for approval. 10.1.4 Acceptance of the materials shall be subject to inspection, approval and release by the inspection agency designated by Owner. Inspection will be carried out as per the scope of inspection detailed in this specification and as per the relevant standard, for which all arrangements/ facilities shall be made by successful bidder. 10.1.5 Painting shall be in line with Painting specifications. 10.1.6 Test certificates should make specific mention that the valves conform to its relevant Standard. It should also include the date of manufacture and surface preparation/ painting. 10.1.7 Chemical composition and mechanical properties shall be checked as per relevant material standards and this specification, for each heat of steel used. a) Non-destructive examination of individual valve material and components consisting of, but not limited to castings, forgings, plate and assembly welds shall be carried out by the Manufacturer.

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b)Body castings of all valves shall be radio-graphically examined on 100% of the surface of critical areas as per ASME B16.34. Procedure and acceptance criteria shall be as per ASME B16.34. 10.1.8 All valves shall be tested in compliance with the requirements of API598/ API609. During pressure testing, valves shall not have sealant lines and other cavities filled with sealant , grease or other foreign material. The drain ,vent and sealant lines shall be either included in the hydrostatic shell test or tested independently. No leakage is permissible during hydrostatic testing. The body cavity self-relieving feature meeting the requirements of this specification shall also be checked. 10.1.9 A supplementary air seat test as per API609 shall be carried out for all valves.

a. A bubble tight seal is required without the use of any sealant. No leakage is allowed. Test pressure shall be held for at least15minutes.

b. Valves shall be subjected to Operational Torque Test as per supplementary test Requirement of API609 under hydraulic pressure equal to maximum differential pressure

corresponding to the valve rating.

c. Valves shall be subjected to anti-static testing as per supplementary test requirement of API609.

10.1.10 10% of valves for each size shall be tested after assembly of the valve and actuator at the valve Manufacturer‟s works. At least five open-close- open cycles without internal pressure and five open-close-open cycles with maximum differential pressure shall be performed on the valve actuator assembly. The time for full open to full close shall be recorded during testing. If required, the actuator shall be adjusted to ensure that the opening and closing times are within the limits stated in Actuator Data Sheet issued for the purpose. 10.1.11 In case the tests do not meet the requirements, retesting/rejection of the lot shall be decided by Owner‟s Inspector. 10.1.12 Owner reserves the right to perform stage-wise inspection and witness tests as indicated above at Manufacturer‟s works prior to shipment. Manufacturer shall give reasonable access and facilities required for inspection to the Owner‟s Inspector. 10.1.13 Owner reserves the right to require additional testing at any time to confirm or further investigates a suspected fault. The cost incurred shall be to Manufacturer‟s account. In no case shall any action of Owner or his Inspector relieve the Manufacturer of his responsibility for material, design, quality or operation of valves. 10.1.14 Inspection and tests performed/ witnessed by the Owner‟s Inspector shall in no way relieve the Manufacturer‟s obligation to perform the required inspection and tests.

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10.2 Actuator For ROSOVs the following tests shall be provided prior to shipping: ♦ Actuator operation, Cycle (open-close) each valve with its actuator at least five times, for proper actuator operation. Verify that valve position coincides with position indicators. ♦Opening-closing position ♦Actuator output speed & Open-Close time ♦Actuator travel setting ♦Operational torque test as per API609. 10.3 Test Certificates

10.3.1 Manufacturer shall submit the following certificates:

a)Mill test certificates relevant to the chemical analysis and mechanical properties of the materials used for valve construction as per the relevant standards. b)Test certificates on hydrostatic and pneumatic tests complete with records of timing and pressure of each test. c)All other test reports and certificates as required by API598/ API609 and this specification. The certificates shall be valid only when signed by TPI. Only those valves which have been certified by Owner‟s Inspector shall be dispatched from Manufacturer‟s works. 11.0 Spares & Accessories 11.1 Manufacturer shall furnish list of recommended spares and accessories for valves required during start-up and commissioning. 11.2 Manufacturer shall furnish list with price of recommended spares and accessories required for two years of normal operation and maintenance of valves. 12 Documentation : All documents shall be in English language. 12.1 Documentation with offer: Bidder shall submit the following documents along with offer:

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12.1.1 General arrangement/ assembly drawings showing all features and relative positions and sizes of vents, drains, actuator, painting, coating and other external parts together with over all dimensions along with weight, air consumption, minimum air pressure requirement &opening-closing time. 12.1.2 Sectional drawing showing major parts with reference numbers and material specification. In particular, a blow-up drawing of disc seat assembly shall be furnished complying the requirement of this specification. 12.1.3 Sizing calculations for selected actuator. Torque curves for the actuators along with the break torque and maximum allowable stem torque. In addition, sizing criteria and torque calculations shall also be submitted for actuated valves. 12.1.5 As a mandatory requirement, Bidder shall firm up the Make &Model of actuator, other accessories like limit switches, SOV, AFR, etc.at the time of submission of bids & same shall not be changed after PO placement. Bidder shall submit de-codification sheet for each type and size for valve and actuator along with torque value . 12.1.6 Descriptive technical catalogues of the Manufacturer. 12.1.7 Details of support foot, including dimensions and distance from valve centerline to bottom of support foot 12.1.8 Manufacturer who intends bidding, must submit at bid stage, certificate report for successful fire type-tests for valves in accordance withAPI-607/ BS EN 12266(Part 2)/ API6FA, as applicable in Valve Data Sheet along with copy of valid API-609 Certificate. Failure to comply with this requirement shall be a cause of rejection of the offer. 12.1.9 Details for calculating overall Safety Instrumented Systems SIL assessment which requires inputs from each SIS device manufactures who contributes in SIF like Initiators, Logic Solver & Final Control element, hence it is implied on actuated valve OEM to provide all necessary information viz SIL Certification, Functional Safety Manual, PFDAVG, SFF, TProof,, λNE, λS, λD for individual devices of actuated valve & then complete package i.e. full actuated valve. 12.1.10 Details of manufacturing / testing facilities available with the bidder and rated production capacity. 12.1.11 Detailed bar chart showing different stages of design, manufacture, testing and dispatch schedules. 12.1.12 Deviations from specifications and attachments if any. 12.1.13 QAP formats duly filled and signed. 12.1.14 Confirmation regarding the codes & standards specified for different works.

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12.1.15 List of recommended spares and accessories for valves &actuators for startup & commissioning. 12.1.16 List of recommended spares and accessories for valves & actuators for 2(two) years normal operation. 12.1.22 Guarantee for performance, workmanship & materials of construction. 12.2 Documentation after Purchase Order placement: 12.2.1 Within three weeks of placement of order, the Manufacturer shall submit six copies of, but not limited to the following drawings/ documents for Owner‟s approval: a) Sizing of actuator & selected model for approval. b) Detailed sectional arrangement drawings showing all parts with reference numbers and material specifications. c) Assembly drawings with overall dimensions and features. d) Hazardous area classification for valve accessories, electrical power consumption for each type and size of valve for approval e) Installation requirements f) QA plan for approval Manufacture of valves shall commence only after approval of the above documents. Once the approval has been given by Owner, any changes in design, material and method of Manufacture shall be notified to Owner whose approval in writing of all changes shall be obtained before the valve is manufactured. 12.2.2 Manufacturer shall submit one reproducible and six copies of the following: a) Test certificates as specified in specification. Inspection certificates & test reports shall be supplied for all mandatory test as per the applicable codes. b) Manual for installation, erection, maintenance and operation instructions, including a list of recommended spares for the valves. c) Details of corrosion resistant paint to be applied on the valves. 12.2.4 Material test and analysis certificates (physical properties, chemical composition & heat treatment report) shall be furnished for the valves supplied. Material test certificates for other parts shall also be furnished during inspection. 12.2.6 Other relevant information/drawings/ documents as required by Owner.

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12.2.7 All the above documents shall be in addition to those mentioned in individual specifications of valves. 12.3 Documentation & Drawings: Six sets of final documentation shall be submitted in hardcopy and softcopy. 12.3.1. General arrangement/ assembly drawings showing all features and relative positions and sizes of vents, drains, actuator, painting, coating and other external parts together with over all dimensions, Sectional drawing showing major parts with reference numbers and material specification , In particular a blow-up drawing of Disc-seat assembly. 12.3.2. Sizing of actuator & selected model with torque details for valves & actuators 12.3.3. Overall general arrangement and dimensional cross sectional drawings of valves, showing part list, material list, weights etc. 12.3.4. Actuator Make, Model, details of selection based on torque, air & electrical power consumption for each type and size of valve. 12.3.5. Inspection certificates & test reports shall be supplied for all mandatory test as per the applicable codes. 12.3.6. Operation and maintenance manual. 12.3.7. Installation requirements.

12.3.8. Calibration certificates, Technical catalogue for valves, actuators & all accessories mounted on valve.

13.0 COMMISSIONING ASSISTANCE & WARRANTIES AND TRAINING: 13.1 Vendor shall depute his commissioning engineer to all locations as covered in Purchase order for commissioning supervision of valves and actuators & stabilization of valve & actuators operations without any extra charges. The representative shall ensure that the actuator is commissioned successfully. All expenses for site services shall be borne by manufacturer/vendor bidder. 13.2 Vendor shall provide warranty for the performance of valves for 18 months from date of dispatch or 12 months from date of installation, whichever is later subject to not exceeding 24 months from date of dispatch. 13.3 Manufacturer shall have / develop adequate service support in India to provide technical after sales service in India with in 48 hrs. Notice & shall guarantee supply of parts, services for at least 10 years for all valves supplied by way of an undertaking. 13.4 Site training ( At Owner works) : The scope of work of vendor shall include co-ordination,

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arranging faculty, bring them to Owner's training center, arranging lodging and boarding, transportation etc. for Training of Owner's personnel. Owner's responsibility will be limited to providing Training hall with all requisite training aids and arranging food / snacks during training session. The training program will comprise of classroom training and explanation of details of valves. The group to be trained will comprise of persons from all disciplines of maintenance, operation and other associated departments. The specialist installation / commissioning engineer(s) of valves will conduct the training covering operational and maintenance aspects. Training shall be arranged for Multidisciplinary group. Vendor shall arrange to provide one day trainings at site engineers / operators on operations & maintenance of valves. (One day Training at 10 locations in India for 12-15 persons each) 13.5 Deleted. 13.6 Manufacturer shall guarantee that the materials and machining of valves and fittings comply with the requirements in this specification and in the Order. 13.7 Manufacturer is bound to replace or repair all valve parts which should result defective due to in adequate engineering or to the quality of materials and machining. 13.8 If valve defect or malfunctioning cannot be eliminated, Manufacturer shall replace the valve without delay. 13.9 Any defect occurring during the period of Guarantee shall be attended to by making all necessary modifications and repair of defective parts free of charge to the Owner as per the relevant clause of the bid document. All expenses shall be to Manufacturer‟s account. 14.0 Site Service/Site Visits by Experts for TAS . 14.1 ROSOV‟s (ESDVs): Valve Vendor shall depute expert service engineer/engineers to site, for co- ordination with TAS contractor for complete integrated testing of the system & stroking of the valves 15.0 Painting, Marking and Shipment 15.1 Actuated Valve assembly surface shall be thoroughly cleaned, freed from rust and grease and applied with sufficient coats of corrosion resistant paint. Surface preparation shall be carried out by shot blasting to SP-6 in accordance with “Steel Structures Painting Council– Visual Standard SSPC-VIS-1”. 15.2 Manufacturer shall indicate the type of corrosion resistant paint used in the drawings submitted for approval.

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15.3 All valves shall be marked as per API 609.The units of marking shall be metric except Nominal Diameter which shall be in inches. Marking shall be done by die-stamping on the cover or on the housing. 15.4 Valve ends shall be suitably protected to avoid any damage during transit. All threaded and machined surfaces subject to corrosion shall be well protected by a coat of grease or easily removable Rust Preventative material. All valves shall be provided with suitable protectors for flange faces, securely attached to the valves. All valve openings shall be positively sealed by suitable blanking plates or plastic plugs. Adhesive tape sealing of opening without blanking plates or plugs will not be acceptable. 15.5 All sealant lines and other cavities of the valve shall be filled with sealant before shipment. 15.6 Packaging and shipping instructions shall be as perAPI609 and procurement documentation. Packaging shall be in accordance with the Project packing Specification. 15.7 All valves shall be transported in the fully close condition 15.8 On packages, following shall be marked legibly with suitable marking ink: a) Order Number b) Manufacturer‟s Name c) Valve size and rating d) Tag Number– at least on 3 sides of packing, legible from distance. e) Serial Number 16.0 Storage

16.1 Valves and components must be stored under cover and out of contact with the ground and

SHALL NEVER BE EXPOSED TO WETTING BY SALT WATER OR SALT SPRAY.

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DATA SHEET – VALVE

1. Valve Size

As per BQO

DESIGN PARTICULARS

2. Valve Type

Triple Offset high performance , metal to metal seated, non-rubbing, torque seated, double flange end, quarter turn, anti-static, anti-blow out stem arrangement butterfly valve. Complete actuated valve shall be minimum SIL2 capable certified by third party agencies like TUV/Exida

3.

Mfg. Standard

API 609

4 Face to Face

As per API 609, Long Pattern/ASME B 16.1

5 Inspection and Testing

API 598

6 Fire Safe API 6FA/API-607-Vth Edition, Zero leakage before, during after fire.

API 6FA/API-607-Vth Edition, Zero leakage before, during and after fire.

7 ANSI Class

150#

8 Rated Travel

90 Degrees

9 Flow direction

Bi-directional, tight shut-off in either direction

10 Fire Safe

Required

11 Anti Static Device

Required

CONSTRUCTION

12 Body

Cast (in Single Piece)

13 Disc

Cast

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14 Stem Bar-forged (No casting)

Bar-forged (No casting)

15 End Connection

Double flanged as per ANSI B 16.5RF

16 Flange & finish

150#, RF, 63-125 AARH, smooth finish

MATERIAL 17 Body

ASTM A216 Gr. WCB

18 19

Disc Seal Ring

ASTM A216 Gr. WCB/ASTM A105 UNS S 31801/31803 Duplex SS+ Graphite

20 Stem/Shaft

ASTM A182F6a/ASTM A 479

21 Bushing

UNS S31600

22 Disc Retainer Flange

ASTM A 516

23 Disc and Bottom Flange

UNS 31600+ Graphite

24 Seat

Stellited Gr. 21 Weld Overlay

25 Pin/Nut/Washers

SS 316

26 Thrust Bearing

SS 316/ Hardfaced /Cobalt based alloy

TESTING 27 Body Hydro-test

1.5 times the flange rating (30 bar #150)

28 Seat Hydro-test

22 bar #150, test duration as per standard

29

Pneumatic Seat

NA (6 bar # 150) inline with API 598

Test

30 Leakage Class required

Zero Leakage/ bubble tight shutoff

SPECIAL REQUIREMENTS

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General Notes: 1. BTS: Bidder to Specify 2. Approved makes for Air Filter: Norgren, Festo, SMC, Legris

31 Safety Integrity Level

Minimum SIL2 capable for actuated valve when it is Type A Device

32 SIL Certification Std.

IEC 61508

33 Third Party Certification

TUV/Exida

ACCESSORIES FOR ROSOV 34 Dust Excluder

N.A.

35 Quick Exhaust Valve

N.A.

36 Fire Safe Box

N.A.

37 Volume/ Buffer Tanks

N.A.

38 Port Protector

N.A.

39

Pilot Valve

N.A.

40 Make & Model

BTS

41 Weight in kgs

BTS

PROCESS DATA 42 Design Pressure

As per #150

43 Design temperature

-5 to +65 55 deg. Centigrade

44 Fail Action

Fail to Close

45 Valve Torque+25% safety margin

BTS

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3. Approved makes for Proximity limit switches: Honeywell, Topworks 4. Approved makes for Pneumtic fittings & tubes: Swagelok, Sandvik, Parker 5. Approved makes for Exhaust Valve: Scradder, SMC, Festo, Legris

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DATA SHEET – ACTUATOR (Pneumatic)

1 Sizing basis 1.25 times the valve torque for shut-off pressure and less than valve stem shear torque

DESIGN PARTICULARS 2 Actuator Type Pneumatic , spring return, air fail to

close, quarter turn, self-lubricating type, suitable for TOBV on-off control, complete actuated valve shall be minimum SIL2 capable when classified as Type A device, certified by third party agencies like TUV/Exida Scotch & Yoke design for valves of all sizes Minimum SIL2 capable when classified as Type A device

3 Spring action Close (Air Fail to close) SCOTCH & YOKE (CONSTRUCTION/ MATERIAL)

4 Housing Carbon steel 5 Yoke Carbon Steel 6 Yoke Bearing Bronze 7 Guide Block Alloy Steel 8 Guide Bar Alloy Steel 9 Guide Block Bearing Steel+ Bronze +PTFE 10 Travel Stop Screw Carbon Steel 11 Piston Carbon Steel 12 Piston Rod Alloy Steel 13 Piston Rod Seal NBR Rubber 14 Piston Rod Bearing Steel + Bronze +PTFE 15 Piston Seal O Ring NBR Rubber 16 Cylinder Carbon Steel 17 Cylinder Seal O Ring NBR Rubber 18 Tie Rod Alloy Steel 19 Spring Carbon Steel 20 Spring Container Carbon Steel 21 Guide Rod Alloy Steel 22 Container Rod Alloy Steel 23 Rod Bearing

Steel + Bronze+ PTFE

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AIR SUPPLY 24 Max Allowable

Pressure 10 kgs/ sq cms (g) Min. Pressure 4.0 kgs/sqcms (g)

25 Available Air Supply 4.5 to 6.5 kg/sqcms (g) 26 Pneumatic Tubing ½” size SS 316, 0.049” thickness OTHER 27 Orientation 90 deg. To pipeline axis 28 Stroke Time Open & close : min 30sec max 60 sec 29 Hazardous Area

Protection Zone 1, Gr. IIA/IIB, T3

30 Ingress Protection IP 65 as per IEC 529 ANCILLARIES 31 Air Filter Regulator Metal body, 5 micron gauge, SS tubing

and auto drain 32 Solenoid Valves As per SV Data Sheet 33 Valve monitor Required 36 Air Relief Valve Not required 37 Local Field Panel Required 38 Limit Switches Micro switches -SPDT, 2 nos for each

ROSOV, Contact rating: 230 V AC/ 24 V DC Operation. IP 65, Die Cast Aluminium, 2 cable entries with certified plugs

39 Make & Model BTS 40 Weight in kgs BTS 41 Air Consumption BTS in Ltrs (for one cycle Open-Close-

Open) 42 Approved makes Rotork, Biffi, Neles, Adams,Emerson

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Notes: 1. Field Push button outside the dyke required for closing of the valve 2. Based on closing time requirement, bidder shall provide flow control valve in actuator vent and with suitable locking arrangement applied after proper setting. 3. These ROSOVs are part of SIS and used as Emergency Shut Down Valves for tank overfill protection. Complete actuated valve assembly shall be SIL3 capable as per IEC 61508, certified by third party agencies like Exida/TUV. To calculate PFD (AVG) , the ESDV PFD and SFF is required. Bidder shall submit the same with the technical offer along with third party certifications and Functional Safety Manual. 4. All accessories like SOV shall also be SIL3 capable. Individual SIL certification shall be submitted. 5. The actuator shall incorporate a safety feature such as a spring cartridge to prevent the accidental release of spring tension during servicing. The actuator spring shall be fully enclosed in a metal housing and permanently treated to resist atmospheric corrosion. The type of treatment shall be manufacturer‟s standard unless otherwise stated. Cadmium or zinc plating (galvanizing) of actuator spring is not permitted. 6. Instrument Air filter with pressure gauge shall have built-in relief suitable for 10 kgs/sqcms to prevent over-pressurization. 7. At no time shall a pressure regulator or any other means be used to limit/reduce actuator torque. The actuator shall withstand the maximum allowable air supply pressure. 8. Actuator design shall be self-lubricating type

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DATA SHEET – SOLENOID VALVE 1 Quantity One for each ROSOV GENERAL

2 Valve Type 3/2 Direct acting universal type, suitable for fail safe operation (de-energised to trip), SIL2 Certified having capability for use in SIL 3 application.

3 Fluid Instrument Air 4 `

Fluid Data

a. Inlet Pressure Min./Max. b. Design Pressure (Shutoff diff.) c. Flow d. Temperature

4.0/7.5 kgs/sq.cms. 10 kgs/sq.cms BTS 65 55 Deg. Centigrade

5 Humidity 95% Relative Humidity 6 Area Classification Zone 1, Gr. IIA/B, T3

SOLENOID VALVE DATA 7 Type- Operation 3 way Universal 8 Action Direct 9 Body Size BTS 10 Port BTS 11 End Connection ½” NPTF 12 Body Material SS316 13 Trim Material SS316 14 Packing-soft seals PTFE 15 Enclosure Protection IP 65, Flameproof-Zone 1, IIA/B, T3

Certified 17 Type of Energisation Continuous

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18 Power Supply a. Operating Voltage-Energisation b. Drop Out Voltage c. Power Consumption

230 V AC / 50 Hz BTS BTS

19 Coil a. Type of Coil b. Style of coil

Single-Suitable for specified Haz. Area Class

c. Insulation class d. Cable Entry e. Cable Gland f. Terminals g. Other wetted parts h. Leakage

Standard Class F or better as per IEC60085/IS1271 ½” NPT(F)+Plug SS 304, double compression Internal for 2.5sqmm conductors Vendor‟s design

Zero Leakage

SPEC. ACC. 20 Mounting

Solenoid valves with mounting brackets

21 Name Plate

SS 304

22 Documents- Catalogue/Manual

Installation/ Operation instructions to be supplied

23 Certification

CCOE/CMRI type approvals to be submitted

24 SS tubing

As required

25 Cable glands/Reducers/Plugs/Shrouds

Shall be supplied suitable for haz. area classification

26 Approved makes for SOV

ASCO/ Herion (Norgren)

Notes:

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9. Suitable anti-vibration terminal blocks shall be provided for cable terminations. Terminals shall be clip-on type (screw less), Phoenix/ Wago make 10. Flameproof Nickel plated brass, double compression cable glands shall be provided. Cable glands shall be covered with shroud. Extra cable entry shall be plugged with suitable E Exd Plug.

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Technical specifications Electro hydraulic actuators 1.0 SCOPE 1.1 This specification covers the requirements for designing, manufacturing, testing & supply of Failsafe Actuator for Remote Operated Shut Off Valve (ROSOV). The actuator shall have local integrated control unit for opening /closing of valves with open/close indications and other essential monitoring and diagnostics indications and controls. It shall have facility for non-intrusive setting of controlling and diagnostics parameters. 1.2 The actuator controls (Close only) and indications (open/close) are also to be provided in a separate flameproof control station l (To be mounted away from actuator outside tank dyke wall by the owner). The actuator shall also have provision for „close‟ from Owner‟s Control Room PLC/DCS. 1.3 The Electro Hydraulic actuator assembly shall be SIL-2 certified and / or capable for standalone to use in SIL – 3 applications. 1.4 The specifications as detailed are minimum requirement and shall be available in the offered actuator model, make & wiring diagram as mentioned in the Actuator Data sheet. 1.5 The specification for Actuator shall be read along with specification for Remote Operated Shut off Valve and this specification together is deemed to cover complete unit of Electro-hydraulic actuator of ROSOV. 1.6 Vendor is required to select the Actuator Model number, rating & various control features as per the requirement of the valve. Accordingly the selected actuator type, model and its control with wiring diagram number, shall ensure the operation of the valve with the desired control. 1.7 Only one make of the actuator (for each type, size and rating of the valve) is to be selected and freezed while submitting the offer. 2.0 CODES AND STANDARDS The equipment shall comply with the requirements of latest revision of the following standards issued by BIS (Bureau of Indian Standards) unless specified otherwise: IS 9334 Electric Motor Operated Actuators IS 13947 (Parts –1, 3, 4&5) Low Voltage Switchgear

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IS4722 Rotating electrical machines – Specification

IS-325 Three-phase Induction Motors IS 2148 Flameproof enclosures for electrical

apparatus IS 4691 Degrees of protection provided by

enclosure for EN 50018 Electrical Apparatus for Potentially

Explosive Atmosphere [EEx(d)]

API RP 500 C Recommended Practice for Classification of Locations for Electrical Installations at Petroleum Facilities Classified as Class I, Division I and Division 2

IS 5572 Classification of hazardous areas (other than mines) having flammable gases and vapours for electrical installation

NEMA 6 Enclosures constructed for either indoor or outdoor use to provide a degree of protection to personnel against incidental contact with the enclosed equipment

IEC 529 Classification system for the sealing effectiveness of enclosures of electrical equipment

BS 5501 Electrical apparatus for potentially explosive atmospheres

IEC 60079 Electrical apparatus to explosive gas atmosphere.

IEC 60529 Classification of degrees of protection provided by Enclosures (IP codes).

IEC 60801 Electromagnetic compatibility of Industrial-Process management and control equipment

IEC 61508 Functional Safety of Electrical/Electronic/ Programmable Electronic Safety Related Systems

IEC 61511 Functional safety ---- Safety Instrumented Systems for the Process Industry Sector

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2.2 In case of imported equipment, the standards of the country of origin shall be applicable if these standards are equivalent or more stringent that the applicable Indian standards. 2.3 The equipment shall also conform to the provisions of Indian Electricity Rules and other statutory regulations currently in force in the country. 2.4 In case Indian standards are not available for any equipment, standards issued by IEC/ BS/ VDE/ IEEE/ NEMA or equivalent agency shall be applicable. 2.5 In case of any contradiction between various referred standards / data sheets and statutory regulations, the following order of decreasing priority shall govern:

- Statutory regulations - Data sheets & Job specifications - Codes and standards - Manufacturer‟s standards

2.6 The actuator and its associated materials/parts shall be designed, manufactured & tested conforming to latest editions of the applicable Indian Standards and / or API RP, including the standards as per Annexure VI, except where it has been modified and/or supplemented by these specifications. 3 VENDOR REQUIREMENTS 3.1 The Vendor should provide the actuator of Specified Make only. 3.2 The vendor shall provide confirmation of spare parts availability from the actuator manufacturer for the next 15 years. 3.3 The offered Actuator make /model shall have proven track record for its satisfactory working for atleast last 2 years 4 TECHNICAL SPECIFICATIONS Each actuator unit shall include the motor, hydraulic pump, hydraulic manifold, accumulator, in-built safety system, pressure sensor indication of hydraulic oil pressure along with position indicators, limit switches, electrical & hydraulic controls, terminal box etc. as a self-contained unit. The actuator shall be sized to provide adequate torque and/ or thrust to ensure the complete intended travel of the valve under the extreme operating conditions.

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The actuator unit shall be double sealed type, watertight and dustproof conforming to IP65 minimum. Any electric/electronic parts inside the actuator assembly shall be adequately protected and suitable higher rating of degree of protection shall be provided. The body of actuator assembly shall be of anodized aluminum and all piping to be of SS316. All the fittings shall be of Swagelock/Parker only. Enclosure shall be rated explosion proof Ex “d” and suitable for installation in Zone 1IIA/IIB, Temperature Class T3 electrical area classification. The actuator shall be sized to guarantee valve closure and provide sufficient thrust to position and fully stroke the valve against the maximum differential pressure that may develop under the specified process and/or start-up conditions. Particular attention shall be paid to unbalanced dynamic forces on the valve disc. For actuator sizing, the shutoff differential shall be considered at full differential pressure. The full differential pressure for actuator sizing shall be assumed as the maximum upstream pressure with the valve fully closed and downstream pressure as atmospheric. The operating speed for valve closing and opening rate shall be at approximately 1-2 second per inches size of the valve. Two selector switches (lockable) shall be provided on the actuator, one for Local/Stop/Remote selection, and with pad-lockable for each position and the other for Open, Close and Stop Commands. Electronic “latching” shall be provided for the torque sensing system to inhibit torque off during unseating or during starting in mid-travel against high inertia loads. A jammed valve protection circuit shall de-energize the motor after a few seconds, if no movement occurs after receipt of a signal to open or close. A local LCD display shall be provided for monitoring continuous indication of the actuator position. A separately sealed compartment containing segregated power and control terminals shall be provided. Earthing terminals shall be provided at the external of ROSOV. 4.1 Actuator Torque Requirement “Actuator design torque” shall be based on maximum valve pressure rating ANSI Class #150 at design temperature and additional safety margin of 25% (1.25x). It actuator shall be capable of opening the valve with the maximum differential pressure across the valve (equal to the maximum specified design pressure on one side and atmospheric pressure on the other side). It shall be based on a valve torque test as defined in API 6D, Appendix-C. VALVE ACTUATOR

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1. (Start-to-close torque)/ (Start-of-stroke torque close)/ (Open-to-close break torque)

Spring-start-torque (SST) A safety margin of 1.25 x shall be applied on top of the valve start-to-close torque. (i.e. 25% more)

2. Running Torque Spring-running-torque (SRT). A safety margin of 1.25 x on top of the required valve running torque shall be maintained. (i.e. 25% more)

3. Reseat Torque/ (Closing torque)/ (End-of-stroke torque)

Spring-end-torque (SET) A safety margin of 1.25 x on top of the valve closing torque shall be applied. (i.e. 25% more)

The Bidder shall specify maximum actuator torque. The Bidder shall specify and tabulate in his quotation the required torque figures for each valve and the delivered torque figures by the. The torque values shall be expressed in Newton meter (N-m) and shall be given for the following valve positions: o Start to open torque (breakaway torque) o Lowest running torque during opening of the valve o End of opening torque (valve fully open) o Start to close torque (breakaway torque) o Lowest running torque during closing of the valve. o End of closing torque (reset torque, valve fully closed). Bidder shall mention in the offer the values of the torque for – Va lve s te m s he a r torque . Ma ximum torque output of a ctua tors . 5 ACTUATOR UTILITY 5.1 The Actuator shall be suitable for the following valve:

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a)

Type of Valve Triple Offset Butterfly Valve

b)

Size of valve Various Sizes

c)

Valve design As per specific requirement

d) Valve Pressure Rating As per specific requirement

e) Installation Outdoor g)

Location of FLP Control panel

Outside tank dyke wall

h)

Location of Owner Control panel

Control building

6 GENERAL REQUIREMENTS 6.1 Summary The Actuator shall be suitable for continuous operation under the specified ambient & service conditions. The vendor shall provide a statement defining the availability, reliability and maintainability of his equipment in relation to defined product lifetime expectancy. Design of the Actuator should be such that inadvertent access to live parts is avoided. Actuator shall be suitable for operating in tropical climate and under the ambient conditions as specified. The Actuator shall be new and specifically produced against the order. The actuator shall be a electro-hydraulic unit complete with sealed hydraulic, electronic and termination compartment. The actuator shall be fail safe type. For fail safe operation, the actuator shall utilize internal spring return mechanism for safe position on loss of power supply and/or ESD. 6.2 Area Classification Actuator and separate control panel shall be suitable for Class-I, Division-I, Gas Group C&D as per API RP 500 C or Class-I, Division-I, Gas Group - IIA & IIB as per BIS -5572 (Indian Standard).

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6.3 Marking The following shall be clearly marked on the nameplate of the actuator : Name of the manufacturer : Model No. : :: Input Voltage : Max torque (N-M) setting : Gross weight : Year of manufacturing : Actuator tag number as per data sheet Hydraulic oil pressure( Normal/Maximum) Hydraulic oil Type Area classification: 6.4 Enclosures The actuator enclosure shall be explosion proof & weather proof suitable for mentioned area classification. The actuator enclosure shall be supplied with fire proof jackets for fire safe operation. The Actuator and the integrated control panel shall be watertight with double sealing conforming to min. IP65 as per IEC- 529/BS5490. Any electric/electronic parts inside the actuator assembly shall be adequately protected and suitable higher rating of protection shall be provided. The Actuator and control panel shall have flame proof designation as EEx(d) IIB T4 CENELEC Norm EN50018,BS5501 certified by BASEEFA UK/ UL/ FM, USA/SIRA Italy. 6.5 Paint Finish Actuator and control panel shall be epoxy painted suitable for exposure at location involving salt spray, high humidity, temp range of - 200 5 deg C to + 700 55 deg C. The epoxy painting shall pass weathering test as per relevant British Standard. 6.6 Electric Motor 6.6.1 Actuator shall be suitable for the ac supply voltage of single (230V AC)/ three phase (415 volt) +/- 10% variation at 50 Hz frequency with +/- 3% variation. 6.6.2 The motor shall have Class `F‟ insulation with temp rise limited to class „B‟.

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6.6.3 Motor shall be housed in a totally enclosed non-ventilating type enclosure. 6.6.4 The motor shall be provided with stall detection device to stop the motor, if motor operation is inhibited. 6.7 Auxiliary Contacts 6.7.1 The Auxiliary switch contacts shall have a minimum rating of 0.25A, 110V DC Non- inductive. 6.8 Torque & Position Limit Settings 6.8.1 “Open” and “Close” position limit settings with adjustable selection shall be provided to ensure correct valve travel. 6.8.2 The internal pressure shall be continuously monitored to prevent excessive torque. 6.8.3 Four limit settings, two at each end of travel for interlocking/ indication, shall be provided. 6.9 Wiring and Terminals All devices provided in the actuator shall be wired up to the terminal block. The contacts for remote operation and indication shall also be wired up to the terminal block. Minimum 10% spare terminals shall be provided for future interlocks. Internal wiring for power and control circuits shall be appropriately sized for ROSOV actuator rating. Each wire shall be identified at both ends using PVC ferrules. The terminal compartment shall be separated from the inner electrical components of the actuator by means of a watertight seal so that the actuator electrical components are protected from the ingress of moisture and foreign materials when the terminal cover is removed during installation and maintenance. The different functional PCB‟s will be slot specific and non-interchangeable among themselves to facilitate easy trouble shooting and replacement. Vendor shall be solely responsible for the compatibility of the actuator with the valve and for the selection and sizing of various electrical devices and components in the actuator. The actuator shall be provided with minimum three adequately sized cable entries viz., one for power cable and two for control cables. However, the actual number of control cable entries in actuator with 2-wire control system shall be provided based on job requirements as specified in data sheets/ specification for control systems for ROSOV Suitable double compression cable glands shall be provided with each actuator for all cable entries and sealing plugs for all control cable entries. The cable glands and plugs shall be made of Nickel-plated brass.

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6.10 Conduit Entries Party shall indicate offered conduit entries in NPT, as per standard design of Actuator & control panel in the enclosed Data Sheet. 6.11 Cable Glands / Reducers Double Compression Flame Proof, Explosion Proof & Weather proof CABLE GLANDS with suitable reducers, shall be supplied. Spare entries shall be plugged with Flameproof Weatherproof plugs 7 CONTROL FACILITIES The control system shall have remote control facility as a standard feature. The remote control circuits shall be powered from internally derived control supply voltage. It shall also have minimum 4 nos. of alarm status contacts indicating the availability of the actuator for remote control/indication for monitoring of the following:

- Loss of one or more phases of power supply - Loss of control circuit supply - Selector switch in local mode - Local stop push button set to “Off” - Any other local fault/ abnormal condition

8 Emergency Shutdown (ESD) ESD functionality shall be based on de-energized to trip condition. ESD functionality shall be performed on actuation any of the following conditions.

Actuation of 24V DC remote command signal from Owner‟s control system. This shall be isolated from control electronics through opto-isolator.

Loss of main power. Loss of hydraulic power Actuation of local/remote push button. Other conditions, as applicable for ESD.

ESD functionality shall close the valve even when the selector switch is on local mode. After an ESD action, normal operation can be restored after normalization of the process and valve opening or closing as the case may be only after resetting the system through resetting through the local pushbutton, or depending upon the configuration

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9 Field Control Unit: The field control unit shall be integral to actuator and shall be powered from the actuator power supply. It shall be configurable locally either with pass word protected in-built key pad or hand held remote configurator. No separate power supply shall be provided for operation of field unit. In both cases, setting of parameters, there will be no opening of covers, and use of any special tools or instruments. Two separate backlit 3&1/2 LCD displays will be provided for indication of actuator parameters and configurations. The field control unit shall be able to execute the following minimum operational commands: • Fully Open/Close the valve. • Emergency shutdown (Hardwired contacts from Owner‟s PLC shall be provided for ESD actuation) • Emergency shutdown (ESD) signal shall over-ride any other signal command . • Capability of 2-wire communication with Owner‟s PLC (through master control station as applicable). 10 Configuration Tool 10.1 The actuator shall have in-built facility for configuration and setting of safety parameters. 10.2 If any external setting tool/ device is required for configuration of settings, the same shall be offered with the actuator & FLP control panel. The external tool shall be intrinsically safe for hazardous area operation. 10.3 One number of such tool per location shall be integral part of the offer and shall be supplied along with the actuator and FLP control panel. 10.4 In case the configuration and setting is to be done from push buttons, no separate external tool is to be offered. 11 INTEGRAL PUSH BUTTON, SELECTOR AND CONTROL DEVICES : The following local control devices shall be provided integral with the MOV actuator:

a) Push buttons for “Open/ Close” selector switch shall be provided. OPEN & CLOSE push buttons should be of green & red color respectively. Close operation shall be push type & Open operation shall be press & rotate type

b) “Local/ off/ Remote Selector switch shall be pad-lockable in each position.

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c) Local continuous position indication from “Valve fully open” to “Valve fully closed”

position, which may be of analogue or digital type using mechanical indication/ Indicating lamps /LEDs.

Also the ROSOV shall have provision for closing from Local Push button (Proposed to be provided outside dyke wall) 12. TORQUE AND TRAVEL LIMIT SWITCHES : The limit switches shall be preset. The switches shall be provided with requisite number of potential-free contacts for valve actuator operation and for indication on remote panels as specified in data sheet. Instead of mechanical torque limit switches, magnetic pulse counter / encoders to measure and control the stroke of actuator may be provided, wherever this feature exists in manufacturer‟s design. 13 Pressure Measurement Internal pressure transducer shall be provided for monitoring the internal hydraulic system pressure and provide alarm for potential stall condition of the valve. The signal of pressure shall be in %age of maximum generated system or actual pressure in 4-20 mA current signal. 14 Two wire control System MOV shall be suitable for two wire control system. This actuator shall have individual field units connectable to master control station through a single 2 wire cable loop for control and monitoring. The vendor shall indicate the maximum number of field units can be connected to a master station and maximum distance from field unit to master station. The vendor shall also indicate maximum number of control input and control/ status output from each field unit that can be handled through 2 wire control system. The MOVs should either have General Purpose FCU card embedded for communicating to any make of Master Station or the FCU should be compatible for direct communication on 'Open Type International Standard 2 wire serial communication protocol/MODBUS for serial communication directly. The following signals shall be available at the Control room:

-Valve open -Valve closed -Actuator fault -Field unit fault -Cable fault -Monitor relay trip -Thermostat trip

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-Local stop selected

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-Local Control selected -Valve Obstructed -Valve jammed

Remote control function shall be provided to permit the actuator to:

-Open fully -Close fully -Assume Emergency Shut Down position

Each field unit /MOV actuator shall be addressable from master control station through unique address code. All the field settable / adjustable parameters of MOV actuator shall be settable from master control room Similarly all the indication available on the MOV actuators shall be available at the master control station. Full diagnostics feature of MOV shall be available on master control room. Suitable redundancy shall be provided such that in case of fault in the cable, the field unit continues to communicate with the master control room. 16 Wiring and Terminals: All devices provided in the actuator shall be wired up to the terminal block. The contacts for remote operation and indication shall also be wired up to the terminal block. Minimum 10% spare terminals shall be provided for future interlocks. Internal wiring for power and control circuits shall be appropriately sized for ROSOV actuator rating. Each wire shall be identified at both ends using PVC ferrules. The terminal compartment shall be separated from the inner electrical components of the actuator by means of a watertight seal so that the actuator electrical components are protected from the ingress of moisture and foreign materials when the terminal cover is removed during installation and maintenance. The different functional PCB‟s will be slot specific and non-interchangeable among themselves to facilitate easy trouble shooting and replacement. Vendor shall be solely responsible for the compatibility of the actuator with the valve and for the selection and sizing of various electrical devices and components in the actuator. The actuator shall be provided with minimum three adequately sized cable entries viz., one for power cable and two for control cables. However, the actual number of control cable entries in actuator with 2-wire control system shall be provided based on job requirements as specified in data sheets/ specification for control systems for ROSOV Suitable double compression cable glands shall be provided with each actuator for all cable entries and sealing plugs for all control cable entries. The cable glands and plugs shall be made of Nickel-plated brass. 17 REQUIREMENTS FOR HAZARDOUS AREAS: Hazardous Area Classification and Protection: Instruments located in hazardous area shall be certified to meet or exceed the electrical hazardous area defined by Area classification .

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The actuator accessories used shall be flame proof and suitable for hazardous area of Zone 1, Group IIA/IIB, T3 or better for applications. Additionally all valve associated instruments shall be weatherproof to IP65./PI67/IP68 as applicable Instruments certified for use in the specified hazardous area classification shall be recognized by authority like FM,CENELEC, PTB, BASSEFA, ATEX , CCOE/PESO etc. Actuators meant for hazardous areas shall meet the requirements of IS 2148, IEC 79 or equivalent international standards . The manufacturer shall possess valid test certificates issue by a recognized independent test house (CIMFR/ Baseefa/ LCIE/ UL/ FM or equivalent) for the offered actuators. All indigenous equipment shall conform to Indian standards and shall have been tested and certified by Indian testing agencies. All equipment (indigenous and imported) shall also have valid statutory approvals as applicable for the specified hazardous locations from Petroleum and Explosives Safety Organization (PESO)/ CCE or any other applicable statutory authority. All indigenous flameproof equipment shall have valid BIS license and corresponding marking as required by statutory authorities. Apart from the nameplate indicating the Tag Number. a separate nameplate shall also be provided on each actuator to indicate the details of the testing agency (CIMER or equivalent), test certificate number with date, statutory approval number with date, approval agency (PESO/ CCE/ DGMS or equivalent), BIS license number with date, applicable Gas group and Temperature class etc. the nameplate shall be riveted/ fixed with screws and not pasted. In case any of the standard details listed above are embossed on the enclosures, the same need not be repeated. Actuator units shall be SIL-2 certified and shall be capable for standalone use in SIL 3 applications, having certification conforming to IEC 61508 / IEC 61511 from TUV/Exida or other accredited international agencies. 18 INSPECTION, TESTING AND ACCEPTANCE : The equipment shall be subject to inspection by Owner or by an agency authorized by the owner. Manufacturer shall furnish all necessary information concerning the supply to Owner. During the course of manufacturing, the purchaser or his authorized representative shall be free to visit the works and assess the progress of work and the manufacturer shall render him all possible assistance to do so. Following routine and acceptance tests shall be carried out at the manufacturers‟ works under his supervision and at his own cost for all the actuators in line with QAP approved by the owners. a. ROUTINE TEST : Functional and calibration test for torque and limit switches b. ACCEPTANCE TESTS : Response time test

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Variation of supply voltage Variation of frequency Tests for motor (As per relevant IS/ IEC) Test on output shaft Any other test as applicable 19 FOLLOWING TESTS SHALL BE PROVIDED PRIOR TO SHIPPING:

Actuator operation, Cycle (open-close) each valve with its actuator at least five times, for proper actuator operation. Verify that valve position coincides with position indicators.

Opening -closing position Actuator output speed & Open-Close time Actuator travel setting Operational torque test as per API 609. The maximum measured torque shall be

less than 75 % of the design torque specified by the valve manufacturer for actuator sizing.

FAT and SAT for the system Two weeks‟ notice shall be given to Owner for witnessing the final testing of the complete assembly to ensure satisfactory operation of the actuators. Type test certificates shall be furnished with bids. Final acceptance of ROSOV at site shall be subject to successful testing of the actuators with the valves. Type test certificates, original drawings referred in certificates and statutory approval certificates and BIS license, where applicable, shall be shown to the inspection agency on demand. The certificates and BIS license must be valid at the time of dispatch. Test certificates of bought-out components shall be shown to the inspection agency on demand. 20 PACKING AND DISPATCH : All the equipment shall be divided into multiple sections for protection and ease of handling during transportation. The equipment shall be properly packed for the selected mode of transportation, i.e. by ship, rail or trailer. The equipment shall be wrapped in polythene sheets before being placed in crates/ cases to prevent damage to finish. The crates/ cases shall have skid bottoms for handling. Special notations such as “Fragile‟. “This side up”, “Center of gravity”, “Weight”, “Owner‟s particulars”, PO no. etc. shall be clearly and indelibly marked on the packages together with other details as per purchases as per purchase order.

13000121-HD-10129 48 of 57

The equipment may be stored outdoors for long periods before installation. The packing shall be completely suitable for outdoor storage in areas with heavy rains and high ambient temperature unless otherwise agreed. In order to prevent movement of equipment/ components within the crates, proper packing supports shall be provided. set of instruction manuals for erection, testing and commissioning, a set of operation and maintenance manuals and a set of final drawings shall be enclosed in a waterproof cover along with the shipment. These precautions shall be read in conjunction with similar specifications for valves. 21 SPARES & SPECIAL TOOLS : 21.1 Vendor shall submit list of standard spares of Actuators along with unit rates with validity for 2 years. 21.2 Vendor shall submit list of special tools, if required for maintenance of Actuators along with unit rates with validity of 2 years. The above shall be submitted in a separate sealed envelope as mentioned in the price-bid formats 22 COMMISSIONING ASSISTANCE : Vendor shall arrange to depute his commissioning engineer to Bhartpur as covered in Purchase order for supervising commissioning activities of actuators without any extra charges. The representative shall ensure that the actuator is commissioned successfully. 23 WARRANTIES: 23.1 Vendor shall provide warranty for the performance of Actuators for 18 months from date of dispatch or 12 months from date of installation, whichever is later. 23.2 In addition, vendor shall also include comprehensive extended warranty of 3 years commencing from the date of expiry of warranty as per clause 10.1 as above 23.3 During the entire warranty period as above vendor shall carry out the preventive

checks(half yearly visits) besides attending to break downs within a period of 72 hours. The scope of the vendor shall also include the spares, tools & tackles etc., visit of service personnel and other travelling/boarding expenses replacement of defective parts free of cost, if any. However , suitable assistance(un skilled labour and lifting tools )if any , required for attending the service/repairs will be provided by the owner.

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24 DATA SHEET FOR ROSOV ACTUATOR : PURCHASERS DATA 24.1 SITE CONDITIONS S.NO. 1.1 Altitude Less than 1000 m Above

MSL 1.2 Design ambient

temperature - 1 deg. To + 55 deg. C

1.3 Humidity max. 100 % 1.4 ROSOV Tag Nos Will be intimated after

award of contract. 24.2 SYSTEM CONDITIONS : S.NO. 2.1 Supply Voltage 415V+ 10%, 3-phase AC

for ROSOV 2.2 Supply Frequency 50 Hz + 3% 2.3 System Earthing Solidly Earthed 24.3 OPERATING ENVIRONMENT : S.NO. 3.1 Area Classification : Zone 1 3.2 Gas Group : IIA/IIB 3.3 Temperature Class : T3 3.4 Construction : Flameproof Ex(d) 3.5 Ingress Protection : IP65 3.6 Painting : Epoxy base 3.7 Fire proofing required : No 3.7.1 For ROSOV Tag Nos : Not Applicable. 3.7.2 With fireproof rating : Not Applicable 4.0 Valve Duty , Mode of Control and Devices for Control 4.1 Valve duty :

Fully open and fully closed Yes.

. Partially open and partially closed No

Control Requirement Local & Remote

for all ROSOVs Setting adjustable parameters of Actuator (

for 2 wire control system) From field & remote thru Master Control Station /

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PLC for 2 wire control

Continuous position indication

Local

Mechanical / Digital indication is required.

Remote – Potentiometer / transducer for remote continuous indication

Required in control room thru‟ Master Control Station

Intermediate travel limit switch Required

Potentials free contacts for indication on remote panel and other interlocks

For Valve Open Position

Required

For Valve Closed Potion Required

For remote indication or position of Local / Remote selector switch

Required

For availability of ROSOV actuator Remote Operation ( contact from monitoring relay)

Required

Remote emergency stop push button for Stopping Actuator

Required

DCS/PLC interface for Remote Control / Indication

Remote Indication required for all ROSOVs

Indication Required

Open/Close Limit Switches Required

Time of operation - Opening & closing Min 30 sec Max 60 sec Make of ROSOV Valve Actuator

Rotork, Biffi, Auma Limitorque or equivalent

Double Compression Glands & plugs ( for unused entries ) , to be supplied with the Actuator

Flame & Weather Proof MOC: SS316SS

Notes : 1. N.A. denotes “ Not Applicable.”

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2. Area Classification Zone, Gas group and Temperature class indicated at 5 Nos. 3.1 to 3.3 above refer to IS/IFC standards. 3. The purchaser shall provide single point power supply to the actuator as per S.No.2 above. Any other control supply voltage required shall be internally derived by the manufacturer within the actuator. 4. Vendor shall furnish complete data as per Part-II of this data sheet for each ROSOV Actuator along with the offer. 5. Remote Input signals for opening / closing / stopping the ROSOV shall be provided through the momentary closing of separate potential free contacts in owner‟s panel. Necessary controls required for running the motor for the complete opening / closing sequence of the valve using such input signals shall be provided by manufacturer in the actuator. 25 Vendor data requirement ROSOV Actuator

S.No.

Description

With Bids

Post order

For Review

For Ref./ Records

1

Vendor Drawing /

* *

Document Submission Schedule

2 List of deviations, if any, to MR requirements

3 Data Sheets (duly filled in

* * *

4 5

G.A and mounting details of actuators Wiring and Connection diagrams

* *

* *

6 QA Plan of Vendor

* *

7 Shop Inspection Plan and * *

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Testing Procedure

8 Test Records

*

9 Type Test Certificates for Flameproof / Explosion proof equipment

* *

10 Recommended maintenance spares with prices

11 Equipment storage procedure

*

12 Data Books / Manuals

a. Installation Manual and Standard b. Operating/Maintenance Manual c. Catalogues / Brochures indicating complete technical details and data for actuator selection

*

*

*

*

13 Details of fireproofing, if specified in data sheet

* * *

Notes : 1. Vendor shall furnish soft copy of all drawings in Auto Cad version 14.0/ 2000 and all documents in MS Office 2000, as part of final documentation. 2. All technical details and documents furnished with bids shall be treated as data for engineering. These shall however, be subject to Purchaser‟s review after order placement and bidder shall comply to MR/Tender requirements without any cost & time implication. 3. Vendor shall submit detailed functionality and Single Line Diagram of the Actuator along with the Technical Bid.

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QAP

13000121-HD-10129 54 of 57

QAP for TRIPPLE OFFSET BUTTERFLY VALVE SCOPE OF INSPECTION

S.

No.

STAG

E/

Activ

ity

CO

MPO

NEN

T

CH

ARAC

TER

ISTI

CS

MET

HO

D

OF

CH

ECK

QU

ANTU

M

OF

CH

ECK

REF

EREN

CE

DO

CU

MEN

TS

ACC

EPTA

NC

E N

OR

MS

REC

OR

D

SUB

VEN

DO

R

VEN

DO

R

TPI/

HPC

L

1.

Inco

min

g M

ater

ial

C

astin

g &

forg

ing

(val

ve b

ody,

D

isc

,sea

l rin

gs ,

stem

, bea

rings

)

Surface Quality Visual As per Mfg Test plan & applicable

code

As per Mfg Test plan & app. code

As per Mfg Test plan & app. code

Inspection Report

P R R

2. Dimensions Measurement

As per Mfg Plan Appr. Drg.

Appr. Drg. Inspection Report

P P R

3. Chemical & Mech. Properties

Review of Vendor

TC

All Heats As per relevant Material

Spec

As per relevant Material

Spec

TC P R R

4. All casting materials

Heat Treatment as per specs

Review of HT

All Lots Relevant Std./Material Spec.

Relevant Std./ Material Spec.

TC P R R

5. Body Casting

Radiography Examination

Radiography 100% of qty.

Relevant Std./Mat Spec.

Relevant Std./ Material Spec.

Film & report

P R R

6. Bars for trim material

Chemical analysis Lab Check All heats Relevant Std./Mat Spec.

Relevant Std./ Material Spec.

Lab report P R R

7. Overlay/ Stelliting using robotic welding machine

Valve body seat ring

Thickness & Hardness of Overlay/Stelliting

Process validation

One test specimen per

material made of base material

As per app. code /spec.

As per app. code /spec.

WPS & WPQ, PQR

- P R

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QAP for TRIPPLE OFFSET BUTTERFLY VALVE SCOPE OF INSPECTION

8. Dimensions checking

seal ring & seat ring

Dimensions checking of

using 3D measurement

tool

One valve per size

As per mfg std or as per app. code

As per mfg std or as per app. code

- P R

Inside micrometer

100% of qty. P H

9.

Boug

ht O

ut

Fini

shed

&

Sub

cont

ract

item

s

Stem

s, G

aske

ts

Gea

r uni

ts,

Fast

ener

s, b

earin

gs,

etc

Surface Defects Visual As per Mgf Sampling

Plan

App DWG / Relevant Std.

App DWG / Relevant Std.

Inspection Report

P R R

10. Dimension Measurement As per Mgf Sampling

Plan

App DWG / Relevant Std.

App DWG / Relevant Std.

Inspection Report

P R R

11. Physical & chemical properties

Review of TC of supplier

As per Mgf Sampling

Plan

App DWG / Relevant Std.

App DWG / Relevant Std.

Inspection Report

P R R

12.

Prod

uct

Eval

uatio

n &

Test

ing

Fin

ishe

d Va

lve

Pressure Shell test

100 % of the valves of all

sizes & types

As per app. code /spec/drg.

As per app. code /spec.

As per app. code /spec.

Test Report

- P W

13. Hydraulic Seat Test at Closing Torque of valve

100 % of the valves of all

sizes & types

As per app. code /spec/drg.

As per app. code /spec.

As per app. code /spec.

Test Report

- P H

14. Anti-static testing (if applicable)

1 valve of each size & type

As per app. code /spec/ drg.

As per app. code /spec.

As per app. code /spec.

Test Report

- P W

15. Torque/thrust functional testing

1 valve of each size & type

As per app. code /spec/ drg.

As per app. code /spec.

As per app. code /spec.

Test Report

- P W

16. Drive train strength test

1 valve of each size & type

As per app. code /spec/drg.

As per app. code /spec.

As per app. code /spec.

Test Report

- P R

17. Fire Safe Test (type Test)

As per app. Code/spec./drg/

As per app. code /spec./drg.

As per app. code /spec.

/drg.

As per app. code /spec.

/drg.

Test Report

- P R

18.

Functional/ Operational

Test (For Motor /Actuator Operated)

As per DWG. 100% by vendor App DWG App DWG Test Report

------

P R

10% by MECON/HPCL

P H

13000121-HD-10129 56 of 57

QAP for TRIPPLE OFFSET BUTTERFLY VALVE SCOPE OF INSPECTION

19. Fi

nal

Insp

ectio

n

Body , Seat & Stem

PMI Check 10% by Supplier & 1 valve of each

size & type by MECON/ HPCL

at random

P R

20. Finished Valve

Visual (TC Verification, SL. No. Marketing

Flange finish, Tag No.) Bevel

Dimensions & Special

Requirement in PO

Visual: 100% &

at random

App DWG App DWG Inspection Report

------

P H

21. Packing Finished Valve

------ At random 100% by supplier As per dispatch

instructions

---- -------

P R

Legends: H-Hold (Offer for Witness & obtain clearance),W-Witness, R-Review, P Perform, A-Approval, I-Information, X-Submit, PO-Purchase Order, PR-Purchase Requisition, Differential hardness – surveillance check & to be taken up before lapping is done normally, , DP-Dye Penetrate Test, UT-Ultrasonic examination, All the NDT-Leak testing/Heat treatment/Special manufacturing procedures have to be specially approved or only previously approved procedures have to be used. In case of conflict between purchase spec., purchase spec. shall be applicable. This document describes generally the requirements pertaining to all types of valves. Requirements specific to the item are only applicable. Abbreviation:

WPS - Welding Procedure Spec. WPQ - Welders Performance Qualification PQR-Performance Qualification Report QAP - Quality assurance plan Mgf - Manufacturing Spec- Spec. App DWG - Approved Drg. TC – Test Certificate

Note: This QAP is to be further developed by Vendor & to submit for approval before manufacturing

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