DOUBLE BLOCK & BLEED AND DOUBLE

ISOLATION VALVES

SPECIFICATIONS FOR

DOUBLE BLOCK & BLEED,

AND

DOUBLE ISOLATION VALVES

Issue and Revision Record:

Revision Date BPCL HPCL IOCL Description

0 23.03.2011 Issued for
Tendering

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INDEX

A) TECHNICAL SPECIFICATIONS : DOUBLE BLOCK & BLEED AND DOUBLE

ISOLATION VALVES

1.0 SCOPE

2.0 APPLICABLE CODES, SPECIFICATIONS & STANDARDS

3.0 GENERAL FEATURES / SPECIFICATIONS

4.0 DESIGN DETAILS

5.0 QUALITY CONTROL / INSPECTION & TESTING

6.0 DOCUMENTATION

7.0 MARKING

8.0 PAINTING / PREPARATION FOR SHIPMENT

9.0 SPARES & SPECIAL TOOLS

10.0 COMMISSIONING ASSISTANCE & WARRANTIES

11.0 TRAINING

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B) TECHNICAL SPECIFICATIONS : FLAME PROOF ACTUATORS

1.0 SCOPE

2.0 CODES & STANDARDS

3.0 GENERAL REQUIREMENTS

4.0 TECHNICAL SPECIFICATIONS

5.0 REQUIREMENTS OF HAZARDOUS AREAS

6.0 INSPECTION , TESTING AND ACCEPTANCE

7.0 PACKING AND DISPATCH

8.0 SPARES & SPECIAL TOOLS

9.0 COMMISSIONING ASSISTANCE

10.0 WARRANTIES

11.0 DATA SHEET FOR MOV ACTUATORS- PURCHASOR’S DATA

12.0 DATA SHEET FOR MOV ACTUATORS- MANUFACTURERES’S’S DATA

ANNEXURE –A : QUALITY ASSURANCE PLANS

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A) TECHNICAL SPECIFICATIONS : DOUBLE BLOCK & BLEED AND DOUBLE

ISOLATION VALVES

1.0 SCOPE :

This specification establishes the technical requirements for Double block &
bleed and double Isolation valves with single operator to be used for positive
isolation purpose for replacement of existing hammer blind valves in Oil
Installations, handling refined petroleum liquid hydrocarbon products
( MS,SKO,HSD,NAPHTHA/ATF/ Ethanol blended Gasoline (up to 10%) etc.

The Size and pressure rating of valves required shall be as per BOQ (Bill of
quantities) of the tender document. The valve shall be conforming to API-6D
specifications & shall bear API-6D monogram.

This specification covers the minimum requirements for the design, manufacture,
Assembly, Inspection, testing, certification & delivery of Manual / electrically
operated Double block & bleed and double Isolation valves complete with all
accessories. Specifications of electrical actuators is covered in section B of this
document.

2.0 Applicable Codes, Specifications and Standards:

2.1 Applicable Codes & standards

2.1.1 The design, manufacture, assembly, inspection, testing and certification

of Double block & bleed and double isolation valves shall be in
accordance with the latest edition of the codes & standards including
amendments as mentioned in the tender specifications. Some of the
standards have been listed below for ready reference :

API-6D Specifications of Pipeline valves

API-6FA Specification for Fire test for Valves.

API-598 Valve Inspection and Testing

ASME B1.20.1 Pipe Threads, General Purpose (inch)

ASME B16.5 Steel Pipe Flanges and Flanged Fittings

ASME B16.10 Face-to-Face and End-to-End Dimensions of Valves

ASME B16.34 Valves – Flanged, Threaded, and Welding End

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ASME B31.3 Chemical Plant and Petroleum Refinery Piping

ASME B31.4 2004 Liquid transportation systems for hydrocarbons and

other liquids

ANSI B46.1 Surface Texture (Surface Roughness, Waviness & Lay)

BS EN 12266 Industrial Valves, Testing of valves, test procedures &

acceptance criteria.

BS-EN Specification for steel forgings for pressure purposes

102222
BS-EN 10213 Specification for steel castings for pressure purposes.

BS 1560 Steel pipe flanges and flanged fittings.

BS-EN 1092 Flanges and their Joints-Circular flanges for pipes, valves,
fittings and accessories, PN designated.

BS-EN 1515-1 Flanges and their Joints.

BS 5146 Inspection and test of steel valves for the petroleum,

petrochemical & allied Industries

MSS-SP-6 Standard finishes for contact faces of pipe flanges and

connecting end flanges of valves and fittings
MSS-SP-25 Standard marking system for valves, fittings, flanges and
unions.

MSS-SP-44 Steel pipeline flanges.

MSS-SP-45 By-pass and drain connection standard

MSS-SP-61 Pressure Testing of Steel Valves

MSS-SP 55 Quality standard for steel castings-visual method.

MSS-SP 61 Hydrostatic testing of steel-valves.

2.2 Deviations to specifications :

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 a 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

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Bidder shall make a formal request with full supporting information.

2.2.3 Only those deviations that are agreed between the Owner and the Bidder will be
Incorporated into the requisition at the time of order.

2.3 Conflicting Requirements :

In case of conflict between the requirements of this specification, API 6-D 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 - This Specification

Second priority - API 6-D/6FA

Third priority - Other Referred Codes & Standards

Fourth 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
FAT Factory Acceptance Test

BPCL Bharat Petroleum Corporation Ltd.

IOCL Indian Oil Corporation Ltd.
HPCL Hindustan Petroleum Corporation Ltd.
POL Petroleum, Oil Installations of Oil Companies

MOV Motor operated valve

HOV Hand operated valve
QAP Quality Assurance plan

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2.5 White Oil Product Details : In the table below, Product Characteristics of the
products in POL terminal are mentioned as general guidelines to bidders

PRODUCT CHARACTERISTICS

Product Flash Specific Vapor Viscosity Pumping

Point Gravity pressure (cST) Temp.(⁰
(⁰ C) (gm/cc) (kg/cm²a) C)
HSD – High > 35 0.82 – 0.86 < 0.4 2-5 @ Ambient
Speed Diesel 40⁰ C
MS – Motor (-) 30 0.73 0.7 < 0.7 Ambient
Spirit
Naptha (-) 20 0.69-0.78 < 0.7 < 0.7 Ambient
ATF – Aviation > 38 0.8 < 0.4 2.56 Ambient
Turbine Fuel
SKO – Super > 35 0.8 < 0.05 1.97 Ambient
Kerosene Oil
MTO- Mineral 33 0.82 0.01 14.92 Ambient
Turpentine Oil
Hexane (-)23.3 0.66 0.37 0.277 Ambient
Ethanol 16.6 0.79 0.08 1.2 Ambient

3.0 GENERAL FEATURES / SPECIFICATIONS:

3.1 The valve shall have one operator only. Gear operation (with or without
reduction gear) shall be provided as per manufacturer‟s specifications /
relevant standards.

3.2 Gear operator shall be provided with position indicators for open/ close
positions, with limit stops as per manufacturer‟s design in line with API-
6D. The operators shall be totally enclosed of helical worm/bevel or
combination of helical worm, bevel and spur gear in grease case with
grease nipples/ plugs or as per specifications of manufacturers with
weather protection.

3.3 Gear operator shall be so designed to operate the valve at break away
torque as defined in API-6D. The maximum force required at the hand-
wheel or wrench to apply the breakaway torque or thrust shall not exceed
360 N (80 lbf). However failing to meet the above requirements vendor
shall offer gear-operated valve and quote as above.

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3.4 Valves with wrench or lever operators shall have “open” position
Indicators with limit stops.

3.5 Wrenches for valves, if required, shall either be of an integral design or

consist of a head which fits on the stem and is designed to take an
extended handle. The head design shall allow permanent attachment of
the extended section if specified by the purchaser. Wrenches that are of
integral design (not loose) shall not be longer than twice the face-to-face
or end-to-end dimension unless otherwise agreed. Hand-wheel
diameter(s) shall not exceed the face-to-face or end-to-end length of the
valve or 1000 mm, whichever is smaller, unless otherwise agreed. Except
for valve sizes DN 40 (NPS 1.) and smaller, spokes shall not extend
beyond the perimeter of the hand-wheel unless otherwise agreed. If
specified by the purchaser, the hand-wheel of the gearbox input shaft
shall be provided with a torque-limiting device, such as a shear pin, to
prevent damage to the drive train. Direction of closing shall be clockwise,
unless otherwise specified.

3.6 Vendor shall be supplying flame proof / PESO,India approved electrical

actuators along with the valves where ever specified in the BOQ.
Actuators of ROTORK, LIMTORQUE, AUMA makes shall be acceptable.
Other makes may be accepted who have proven performance
worldwide since previous 3 years from date of NIT & have well
equipped maintenance & service support in India as on the date of
NIT. Valve vendors to submit full details to verify their full credentials
including performance certificate from 3 major users in the oil industry.

3.7 The valves shall be Expanding gate valves with rising stem having
two piece parallel expanding gates with resilient seats or twin seal
plug valves having two independent resilient Retractable seats. The
valve shall be designed to provide a tight mechanical seal and positive
shut-off under high and low differential Pressures.

3.8 Rotation of the hand wheel/operator while opening shall lift / rotate the
plug or gate without wiping the seals due to retracting action of the
sealing slips so that during rotation / lifting of the plug / gate, clearance is
maintained between the sealing slips and the valve body to minimize
wear & tear of the seals. Rotation of the hand wheel/operator while
closing shall lower the plug or gate after the sealing slips are aligned with
the valve body and force the sealing slips against the valve body for
positive closure independent of line operating pressure.

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3.9 Motor operated valves shall be directly mounted with flame proof
electric actuators / gear operators and delivered to the field as a
complete unit.

3.10 RELIEF SYSTEM: The valves are to be provided with integral thermal relief
system consisting of suitable valves & piping as per ratings of the valves to
relieve the pressure build up in the internal body cavity when the valve is
closed. Relief valves shall open at minimum 25 psi differential pressure or
as specified by the manufacturer within limits as specified under clause 7.8
of API-6D and shall discharge to the upstream side of the valve. Thermal
relief valves shall be externally placed in a way so that the same can
be serviced without dismantling the main valve.

3.11 BLEED VALVES: Manually operated bleed valves are to be provided on

the valve that can be opened to verify that the valves are not leaking when
in the closed position. Suitable discharge piping with isolation valves and
end plug / suitable adaptor for extension purpose, shall be provided so that
the released liquid from each bleed valve can be contained locally. There
shall be a provision to provide necessary instruments for remote
checking of valve integrity in control room, if required by the user
company.

3.12 Vendor shall quote in strict accordance with the valves data/ specification
sheets, subject technical notes and all other enclosures to the tender
document. Any deviation to be highlighted clearly in the deviation sheets
enclosed.

3.13 Vendor shall supply valves along with auxiliaries, if any, such as gear
operator, bypasses, drains etc. wherever specified in the specification
sheets, subject notes and other enclosures to the tender document.

3.14 Valve body shall preferably have provision to drain any muck or dirt
remains inside the Valve body, which can damage the seats.

3.15 The valve bodies shall be suitable for above ground open atmosphere
Installation & shall be suitable for ambient Temperature range of -10ºC to
+ 55ºC & Relative humidity up to 100 %.

3.16 The valve shall be maintainable while being in position either by unbolting
from Top or bottom or both. Valve design shall permit sealing slips to be
replaced from the Top or bottom with the valve mounted in the piping.
Vendor to mention the clearance required below the valve for on-line
maintenance.

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4.0 DESIGN DETAILS :

4.1 Valve shall be designed, manufactured, tested, inspected as per API-

6D/ISO 14313, ASME B16.34 & other manufacturing standards, design
codes and standards (latest editions) indicated in latest edition of API-6D .
Each valve shall bear API-6D monogram.

4.2 Metallic Pressure-containing and pressure controlling parts, including

bolting, shall be designed with materials as per manufacturers‟ standards
complying with minimum requirements as stipulated in clause 8 of API-6D.

All process-wetted parts, metallic and non-metallic, and lubricants shall be

suitable for the commissioning fluids and service specified by the
purchaser. Metallic Materials shall be selected so as to avoid corrosion and
galling, which would impair function and/or pressure containing capability.
Selection of elastomeric materials for valves intended for hydrocarbon gas
service at pressures of PN 100 (class 600) and above shall consider the
effect of explosive decompression.

The wetted parts shall be suitable coated with chrome coating / plating,
Fluorocarbon coating & electro less nickel coating as required to
enhance properties of materials for achieving longer life as per
manufacturer‟s standards & Approved QAP.

Design and calculations for pressure-containing elements shall be in

accordance with an internationally recognized design code or standard with
consideration for pipe loads, operating forces, etc. The choice of standard
shall be in line with API-6D. Pressure & temperature ratings for ASME
class-rated valves shall be in accordance with the applicable rating table
for the appropriate material group in ASME B16.34. Material of
construction of critical components of valves has been tabulated in
Annexure-I.

4.3 Face-to-Face and end-to-end dimensions of valves shall be in accordance

with Tables 2 to 6 of API-6D. Face-to-face and end-to-end dimensions for
valve sizes not specified in Tables 2 to 6 shall be in accordance with ASME
B16.10. Valve connections shall be ASME B16.5, Class 150 or Class 300,
raised face flanged, as specified.

4.4 Positioning of cover must be provided to ensure correct Alignment of the

valve disc part or an arrangement of parts for securing a valve in the open
and/or closed position. Locking devices shall be designed to lock the valve
in the open and/or closed position. The position of the obturator shall not

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be altered by dynamic forces of the passing flow. Valves fitted with manual
or powered actuators shall be furnished with a visible indicator to show the
open and the closed position of the obturator.

4.5 For plug valves, the wrench and/or the position indicator shall be in line
with the pipeline when the valve is open and transverse when the valve is
closed. The design shall be such that the component(s) of the indicator
and/or wrench cannot be assembled to falsely indicate the valve position.
Valves without position stops shall have provision for the verification of
open and closed alignment with the operator/actuator removed.

4.6 Travel stops shall be provided on the valve and/or operator and they shall
locate the position of the obturator in the open and closed position. The
travel stops shall not affect the sealing capability of the valve. Misalignment
or improper assembly of components shall be prevented by suitable
means, such as a dowel pin or fitting bolt, which ensures the correct
location of manual or powered operators and stem extension assemblies.

4.7 The operating levers or handles on valves shall indicate, by their position,
whether the valve is open or closed. The open position shall be indicated
when the lever or handle points in a direction parallel to the flow through
the valve. In addition, it shall be impossible to reverse the indicating
position inadvertently during reassembly of the valve. Suitable marking
shall be done on the valve to indicate flow direction.

4.8 Welding, including repair welding of pressure-containing and pressure-

controlling parts shall be carried in line with clause 9 of API-6D.

4.9 Valve body/ bonnet shall be forged / cast as specified. Forgings are
acceptable in place of casting but not vice versa. For expanding gate
valves, fabricated body ( using steel plates) is acceptable

4.10 Material of construction of yoke shall be minimum equivalent to body/

bonnet material.

4.11 Stem shall be forged or machined from forged/ rolled bar. No casting is
permitted.

4.12 Graphite material used for stem packing shall be chloride free i.e.
leachable chlorides shall be less than 50 PPM.

4.13 Stelliting/ hard-facing by deposition, if required shall be min.1.6mm or as

per manufacturer‟s specifications.

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4.14 Suitable gaskets are to be provided for body bonnet joints as per
Manufacturer‟s specifications in line with the requirement of standards.

4.15 valves shall be supplied with antistatic arrangement as specified in API-

6D

4.16 The MOVs are to be installed in an open area and the actuators shall be
IP-65. The testing of complete assemblies of MOVs along with the
actuators shall be carried out by the supplier at his works.

4.17 Ends of flanged valve of 22” size shall match corresponding flanges to
MSS-SP44 unless otherwise specified.

4.18 For reduced bore valves, Minimum bore size shall be as per API-6D.
Reduced-opening valves with a circular opening through the obturator shall
be supplied with a minimum bore as follows, unless otherwise specified:

�valves DN 300 (NPS 12) and below: one size below nominal size of
valve with bore according to Table 1 of API-6D;
�Valves DN 350 (NPS 14) to DN 600 (NPS 24): two sizes below nominal
size of valve with bore according to Table 1of API-6D;
�Valves above DN 600 (NPS 24): by agreement / as per standards of
manufacture.

Reduced-opening valves with a non-circular opening through the obturator

shall be supplied as per API-6D .

4.19 The valve shall be maintainable on line, without having a need to remove
the valve body from the piping system. Valve seat shall be removable &
replaceable without removing the valve from the manifold or pipe line. For
gate valves, Valve gate, segment and seat rings shall be removable
without removing the valve from the manifold or pipe line for ease of
maintenance.

4.20 Gate/Plug design shall be such that it shall expand only in the closed
position and provide a tight mechanical seal. Increases or decreases in line
pressure shall not affect the mechanical sealing.

4.21 The design of stem protector and position indicator must be rugged and
weatherproof. The position indicator shall be sealed at its exit point from
the stem protector using a suitable mechanism. Operators, stem
extensions and their interfaces shall be sealed to prevent ingress of
external contaminants and moisture. Operators and stem extension

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assemblies shall be provided with a means of preventing pressure build-up

in the mechanism resulting from stem or bonnet seal leakage.

4.22 Valve stem packing shall be designed for easy on-line maintenance. The
stem shall be of anti blowout design, permitting replacement of the stem
seals with the valve in fully closed position. Valves shall be designed to
ensure that the stem does not eject under any internal pressure condition
or if the packing gland components and/or valve operator mounting
components are removed. The stem integrity shall be ensured as per
vendor‟s design.

4.23 Manufacturer of the valve shall ensure bonding of slip seals for
integrity & there shall be established procedures for ensuring QA/QC
of the sealing materials & bonding. Viton material sourced from
DUPONT / 3M shall only be accepted.

4.24 Drain, vent and sealant lines, if required as per design of the valve shall be
provided and shall be extended by means of rigid pipe work, if necessary.
The lines shall be fastened to the valve and/ or extensions and terminate
close to the stem extension top works, by agreement. Drain and vent lines
shall :

�have a design pressure not less than the rated pressure of the valve on
which they are installed;
�be capable of withstanding the hydrostatic shell test pressure of the
valve
�be designed in accordance with a recognised design code;
�be suitable for blow-down operation, where applicable.

Sealant lines for stem sealant injection, if required shall have a design
pressure not less than the greater of the pipeline valve rated pressure and
the injection pressure. If not specified by the purchaser, the manufacturer
shall advise the maximum injection pressure for the system. The size of the
sealant lines shall be by agreement. Prior to assembly, the internal bores of
sealant lines shall be clean and free from rust and any foreign particles.

Drain and vent block valves shall be provided, if specified, shall have a
rated pressure not less than the valve on which they are installed and be
suitable for blow-down operation.

Bypass, drain and vent connections and plug entries shall be drilled and
threaded unless otherwise specified / as per manufacturing standards

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Thread profiles shall be tapered unless otherwise agreed. Tapered threads

shall be capable of providing a seal and comply with ASME B1.20.1.
If the use of parallel threads is specified, the connection shall have a head
section for trapping and retaining a sealing member suitable for the
specified valve service. Parallel threads shall comply with ISO 228-1.
Minimum sizes shall be in accordance with Table 7 of API-6D.

4.25 The pressure as determined in accordance with clause 7.2 of API-6D shall
be the maximum pressure differential (MPD) at which the valve is required
to be opened by the lever, gearbox or actuator. The manufacturer shall
provide the following data to the purchaser in technical bid:

�flow coefficient Cv or Kv;

�breakaway thrust or torque for new valve;
�maximum allowable stem thrust or torque on the valve and, if applicable,
the maximum allowable input torque to the gearbox;
�Number of turns for manually operated valves.

4.26 Drive trains: The design thrust or torque for all drive train calculations shall
be at Least two times the breakaway thrust or torque to allow for thrust or
torque increase in service due to infrequent cycling and the adverse effect
of debris. Allowable Tensile stresses in drive train components, including
stem extensions, shall not exceed 67 % of SMYS when delivering the
design thrust or torque. Shear, torsion and bearing stresses shall not
exceed the limits specified in ASME Code Section VIII, Division 2, Part AD-
132, except that design stress intensity values, Sm, shall be 67 % of
SMYS. These stress limits do not apply to the components of rolling-
element or other proprietary bearings or high bearing strength capable
materials that are included in the drive train where manufacturer's
recommendations or limits derived from tests and service experience
apply. These limits shall be justified in design documents, if requested.
The drive train shall be designed such that the weakest component is
outside the Pressure boundary. A strength efficiency factor of 0,75 shall be
used for fillet Welds .

Note — If an actuator or operator can deliver a thrust or torque that is

greater than the design thrust or torque of the drive train, such a
thrust or torque can result in permanent deformation or failure of
drive train Components. Hence careful selection shall be carried out
for actuator.

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Deflections of the extended drive train shall not prevent the obturator from
reaching the fully closed or fully open position. For all valves, attention shall
be paid to deflection and strain. Adherence to the allowable stress limits of
Design codes alone might not result in a functionally acceptable design.
The manufacturer shall demonstrate, by calculation or test, that under
loads resulting from design pressure and any defined pipe or external
loads, distortion of the obturator or seat does not impair functionality or
sealing.

4.27 Valves of size DN 200 (NPS 8) and larger shall be provided with lifting
points. The manufacturer shall verify suitability of the lifting points. The
valve manufacturer shall verify the suitability of the lifting points for the
complete valve and operator assembly.

4.28 Materials of construction for critical valve components shall be as given

below in table A & B

TABLE –A (DBB PLUG VALVES)

S.NO. DESCRIPTION SPECIFICATION VENDORS

CONFIRMATION
4 Body Cast Carbon Steel ASTM A
216 WCC /WCB
5 Bonnet / Lower Cast Carbon Steel ASTM
plate A516 Gr. 70 / ASTM A 216
WCC/WCB
6 Plug Cast Carbon Steel ASTM A
216 WCC/WCB, case hardened
and 0.003 in. ENP
7 Stem AISI 4140 (1.5 mm steliting) /
ASTM-A479 TY 410 (0.03in.
ENP)
8 Slips Cast Ductile iron ASTM A 536-
80-55-06/ A395 Gr. 60-40-18
9 Gasket Flexible Graphite.
10 Gland packing Flexible Graphite
11 Body Fire seals Graphite
12 Slip seals Viton (Dupont / 3M)
13 Bolts/Nuts ASTM A193 Gr.B7 /ASTM A
194 Gr2H
14 Tubing / SS-316
connectors
/needle valves

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TABLE -B (DBB GATE VALVES)

S. No DESCRIPTION SPECIFICATION VENDORS

CONFIRMATION
1 Body ASTM A 516 GR. 70 / ASTM A
216 GR. WCB/WCC
2 Bonnet ASTM A 516 GR. 70 /ASTM A
216 GR. WCB/WCC
3 Bolts/Nuts ASTM A193 Gr B7/ASTM A
194 Gr2H
4 AISI 4140 (1.5 mm stelliting /
STEM
ENP)
6 GRAFOIL TYPE TO COMPLY
STEM SEAL WITH FIRE SAFE
REQUIREMENT
7
GATE / A216WCC/ WCB or ASTM A
SEGMENT 516(ENP)
8
SEAT ASTM A 516-GR.70 OR A105
ASSEMBLY
9 Centralised ASTM A 516-GR.70(ENP)
arm
10
SEAT SEAL VITON (DUPONT/3M)
11
O-RING
VITON GFLT
SEALS
12
PRESSURE
RELEASE SS-316
VALVE
13 Packing Graphite
14 End Flanges ASTM A 105,125AARH
15 Tubing / SS-316
connectors
/check /needle
valves

4.26 All applicable codes and standards for design, materials, manufacture, testing,
inspection etc. shall be of latest editions. Vendor to list all the specifications /
standards applicable.

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5.0 QUALITY CONTROL / INSPECTION & TESTING

5.1 Valve shall be subject to all the tests and checks required as per quality
control requirements of clause 10.0 & testing requirements of clause 11.0
of API-6D & other relevant standards & as per the QAP specified in the
tender document. However vendor shall submit their detailed QAP in
line with the specifications stipulated in this tender document. NDE
tests shall be carried out in line with Annexure-A of API-6D. Vendor shall
be deploying services of TPIA for witnessing tests as per approved QAP at
their (Vendor‟s) cost. Approved TPIA agencies are:

 TUV,
 Lloyds,
 Certification Engineers India LTD,
 Det Norske Veritas,
 SGS.

5.2 Purchaser, at its discretion may depute their representatives at their own
cost to witness critical tests at manufacturing works in addition to TPIA.

Chemical composition and mechanical properties shall be checked as per

relevant material standards and this specification, for each heat of steel
used.

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 in line with API-6D.

5.3 The manufacturer shall submit a certificate covering the testing of the valves
and Certifying the materials of construction used in the valves, according to
API 6D and other relevant standards of Latest edition.

5.4 Vendor shall submit type test certificates for fugitive emission tests
carried out in accordance with TU-LUFT / ISO 15848 / US Clean air act or
equivalent standards.

5.5 Valves shall be tested prior to shipment in line with the requirements of
API-6D and agreed QAP. Testing shall be performed in the sequence
detailed in API-6D. Pressure testing shall be carried out before coating of
the valves. Test fluid shall be fresh water or, by agreement, light-weight oil
having a viscosity not exceeding that of water. Water used for testing
shall contain a corrosion inhibitor.

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5.6 Valves shall be tested with the seating and sealing surfaces free from
sealant except where the sealant is the primary means of sealing. A
secondary sealant system, if provided, shall not be used before or during
tests.

5.7 Supply pressure shall be stabilized prior to the start of pressure testing and
shall be held for the minimum test durations listed in Tables 9, 10 and 11 of
API-6D.

5.8 Fire type-testing certification of the design shall be provided. The fire-
resistance design of valves shall be qualified by fire type-testing in
accordance with ISO 10497.Fire resistance designs already qualified to ISO
10497, API 6FA, API 6FC, API 6FD or API 607 are also acceptable as per
stipulations of API-6D.

5.9 Hydrostatic shell test: Valve ends shall be closed off and the obturator
placed in the partially open position during the test. If specified by the
purchaser, the method of closing the ends shall permit the transmission of
the full-pressure Force acting on the end blanks to the valve body. If present,
external relief valves shall be removed and their connections plugged. The
test pressure shall be 1,5 or more times the pressure rating determined in
accordance with 7.2 for Material at 38 °C (100 °F). The duration shall not be
less than that specified in Table 10. No visible leakage is permitted during
the hydrostatic shell test.

After hydrostatic shell testing, external relief valves shall be fitted to the
valve. The connection to the valve body shall be tested at 95 % of the set
pressure of the relief valve for 2 min for valve sizes up to and including DN
100 (NPS 4), and 5 min for valve sizes DN 150 (NPS 6) and larger. The
relief-valve connection shall be free of visible leakage during this period. All
the valves are required to be tested for hydrostatic shell test.

5.10 Hydrostatic seat test: The test pressure for all seat tests shall not be
less than 1.1 times the pressure rating determined in accordance with
clause 7.2 of API-6D for material at 38 °C (100 °F). The test duration shall
be in accordance with Table 11. The test procedures for various types of
block valve shall be in line with para 11.4.4.of API-6D

Acceptance criteria:

Leakage for soft-seated valves shall comply with the requirements of API
598. API-598 states for shell and backseat tests, no visible leakage is
permitted. If the fluid is a liquid, there shall be no visible evidence of drops

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 DOUBLE BLOCK & BLEED AND DOUBLE
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or wetting of the external surfaces (no visible leakage through the body,
body liner, if any, and body-to-bonnet joint and no structural damage).

If the test fluid is air or gas, no leakage shall be revealed by the established
detection method. For both the low-pressure closure test and the high-
pressure closure test, visual evidence of leakage through the disk, behind
the seat rings, or past the shaft seals (of valves that have this feature) is not
permitted (Plastic deformation of resilient seats and seals is not considered
structural damage).

The allowable rate for leakage of test fluid past the seats, for the duration of
the tests, is listed in the following table:

All All Metal-Seated Valves Metal-Seated

Resilient (except Check Valves) Check Valves
Valve Size
Seated Liquid Test Gas Test Liquid Test Gas Test
Valves (drops/min) (bubbles/min) (drops/min) (bubbles/min)
<= 2" 0 0 (b) 0 (b) (c) (d)
2.5" - 6"" 0 12 24 (c) (d)
8" - 12"" 0 20 40 (c) (d)
>= 14"" 0 28 56 (c) (d)

Where :

(a) 1 milliliter is considered equivalent to 16 drops

(b) There shall be no leakage for the minimum specified test duration. For
liquid test, 0 drop means no visible leakage per minimum specified test
duration. For gas test, 0 bubble means less then 1 bubble per minimum
specified test duration.

(c) The maximum permissible leakage rate shall be 0.18 cubic inch (3 cubic
centimeters) per minute per inch of nominal pipe size.

(d) The maximum permissible leakage rates shall be 1.5 standard cubic feet
(0.042 cubic meter) of gas per hour per inch of nominal pipe size.

All the valves are required to be tested for hydrostatic seat test.

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 DOUBLE BLOCK & BLEED AND DOUBLE
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Additional seat testing:

Since the valves are expected to have the functionality for the valve to be
that of double-block-and-bleed (DBB) & double-isolation-and-bleed (DIB-1),
the test described in Clause B.10 & B.11 of API-6D shall be performed . 10
% of the valves of all sizes & types are required to be tested for
Additional seat testing.

5.11 Test of thermal relief valve: The external relief valve shall be set and
certified to relieve at the specified pressure either by the relief-valve
supplier or the valve manufacturer for all the valves .

5.12 Testing of drain, vent and sealant injection lines, if provided: drain and
vent Lines shall be subject to a hydrostatic test with all the valves.

5.13 Anti-static testing: The electrical resistance between the obturator and
the Valve body and between the stem/shaft and the valve body shall be
measured using a direct-current power source not exceeding 12 V. The
resistance shall be Measured on dry valves before pressure testing and
shall not exceed 10 ohm 5 % of the valves of each size & type shall be
tested for Anti-static testing.

5.14 Torque/thrust functional testing: The maximum torque or thrust required

to Operate gate or plug valves shall be measured at the pressure
specified by the purchaser for critical valve operations. Thrust and torque
testing shall be performed following hydrostatic shell testing and, if
specified, prior to any low-pressure gas seat testing. The measured torque
or thrust results shall be recorded and shall not exceed the manufacturer‟s
documented breakaway torque/thrust. 1 % of the valves (min.1) of each
size & type shall be tested.

5.15 Drive train strength test: The test torque shall be the greater of
a) Twice the manufacturer's predicted break-away torque/thrust, or

b) Twice the measured break-away torque/thrust.

The test torque shall be applied with obturator blocked for a minimum time
of 1 min.

NOTE :

For gate valves, the thrust can be tensile or compressive,

whichever is the most stringent condition.

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 DOUBLE BLOCK & BLEED AND DOUBLE
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The test shall not cause any permanent visible deformation of the drive
train.

For plug valves, the total torsional deflection of the extended drive train
when delivering the design torque shall not exceed the overlap contact
angle between the seat and obturator.

1 % of the valves (min.1) of each size & type shall be tested for Drive
train strength test.
.
6.0 DOCUMENTATION :

6.1 Vendor shall arrange to retain documents in his works as stipulated in

API-6D.

6.2 In addition, Vendor shall arrange to submit following documents

along with the consignment :

6.2.1 Detailed dimensioned, cross section drawing of each size of valve being
offered with parts/ material lists, weight etc. as manufacturer‟s / API /
Other relevant applicable standard.

6.2.2 Drawings for valves with accessories like gear operator, extension bonnet,
extended stems with stands bypass etc. giving major salient dimensions.

6.2.3 Material test certificates (physical property, chemical composition & heat
treatment report, radiography etc.) of the pressure containing parts & for
the other parts shall also be furnished for verification during inspection.

6.2.4 Following supplementary documentation is required to be provided in line

with API-6D as given below:

a) NDE records;
b) Hardness test report on pressure-containing parts;
c) Heat treatment certification records (e. g. charts);
d) Pressure test / Leak test (Valve seat & Fugitive) & other test reports,
(Including pressure, test Duration, test medium and Acceptance
Criteria);
e) coating/plating certification;
f) Fire type-test certificates;
g) Material inspection certificates in accordance with ISO 10474 or EN
10204, as applicable (the purchaser shall specify the type of
Certification, and for which parts, when ordering);

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h) Design verification by certification body/agency;

i) Installation, operation and maintenance instructions/manuals;

6.2.5 All the documents as listed above shall be submitted in 3 copies

Separately for each purchaser company (BPCL,IOCL & HPCL).

7 MARKING :

7.1 Valve markings, symbols, abbreviations etc. shall be in accordance with

Table 12 of API-6D. Vendors name, valve rating, material designation,
nominal size,direction of flow (if any) etc. as specified in the table 12 of
API-6D shall be integral on the body.

7.2 Body/cover/closure stamping shall be performed using a low-stress die-

stamp, rounded “V” or Dot Face type. Each valve shall be provided with an
austenitic stainless steel nameplate securely affixed and so located that it
is easily accessible. The marking on the nameplate shall be visually
legible.

7.3 Each valve shall be marked with API-6D Monogram

8 PAINTING / PREPARATION FOR SHIPMENT :

8.1 All non-corrosion-resistant valves shall be coated externally in accordance

with manufacturer‟s standards, unless otherwise agreed.

8.2 Carbon steel valves shall be painted with two coats of inorganic zinc
silicate primer ( Min. 35 micron per coat) .
.
8.3 Flange faces, weld bevel ends and exposed stems shall not be coated.

8.4 Parts and equipment that have bare metallic surfaces shall be protected
with a rust preventative that can provide protection at temperatures up to
50 °C (122 °F).

8.5 After testing, all valves shall be drained and dried thoroughly. Valve shall
be suitably painted as above / vendor‟s standard approved specifications.

8.6 Flanged, threaded and welding ends shall be blanked off to protect the
gasket surfaces, welding ends and valve internals during shipment.
Machined surfaces shall be protected against corrosion during shipment
and storage.

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 DOUBLE BLOCK & BLEED AND DOUBLE
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8.7 Valves shall be protected from rust, corrosion and any mechanical
damage during Transportation, shipment and storage. The packages shall
be sea-worthy when required to be transported by ships.

8.8 Rust preventive on machined surfaces shall be easily removable with a

Petroleum solvent.

8.9 Each end of valves shall be protected with the following materials:

Flange Face : Wood, Wood fiber, Metal or Plastic cover

Beveled End : Wood, Wood fiber, Metal or Plastic cover
SW & SCRD End : Plastic Cap

The ends shall be securely attached to the valve ends by bolting, steel
straps, Steel clips or suitable friction-locking devices. The design of the
covers shall Prevent the valves from being installed unless the covers
have been removed.

A warning label shall be attached to the protective cover with instructions to

remove, prior to installation, material from inside the valve that secures or
supports the disc.

Each valve shall be wrapped in a polythene / impervious sheet &

packed separately in wooden crate, properly secured to prevent
damage during transportation. Each box shall be clearly marked,
valve size, location of dispatch, Purchaser company’s name , UP
marking & ―fragile‖ warning.

The valve boxes shall be put in a large container for transportation as

per manufacturer’s standards separately for each Purchaser Company
& location of dispatch.

8.10 The Plug valves shall be shipped in the fully open position. While, gate
valve shall be shipped with the gate in the fully closed position.

8.11 Valves of size DN 200 (NPS 8) and larger shall be provided with lifting
points,Unless otherwise agreed. The manufacturer shall verify suitability of
the lifting points.

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9 SPARES & SPECIAL TOOLS :

9.1 Vendor shall submit list of standard spares of valves & actuators along
with unit rates with validity for 2 years.

9.2 Vendor shall submit list of special tools, if required for maintenance of
valves along with unit rates with validity of 2 years.

10 COMMISSIONING ASSISTANCE & WARRANTIES :

10.1 Vendor shall arrange to depute his commissioning engineer to locations of

IOCL/BPCL/HPCL as covered in Purchase order for attending to any
teething problems related to valve operations, if any, without any extra
charges. The representative shall ensure that the valve is
commissioned successfully.

10.2 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.

10.3 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.

11 TRAINING :

11.1 Site training ( At Owner works) : The scope of work of vendor shall
include co-ordination, 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.

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Training shall be arranged for Multidisciplinary group. Vendor shall arrange

to provide one day trainings at site in all the regions to appraise
Purchaser‟s engineers / operators on operations & maintenance of valves.
(One day Training at 10 locations in India for 12-15 persons each)

11.2 Training at vendor works. The scope will include co ordination for
arranging training for officers at vendor works for 3-4 days. The group
deputed for training will comprise of two multi disciplinary groups of 15
officers each drawn from operation, maintenance departments of all the 3
purchasing companies with a group leader.

All lodging and boarding and traveling expenses of IOCL/BPCL/HPCL

personnel will be borne by owners.

However all requisite training material like literature/documents shall be

provided by the vendor. Vendor shall include cost of such training in their
offer.

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B) SPECIFICATION FOR ELECTRICAL MOTOR OPERATED VALVE

ACTUATORS

1.0 SCOPE :

The scope of this specification covers design, manufacture, assembly, shop

testing and supply of electrical motor operated valve actuators intended for fully /
partially opening and closing valve duty.

2.0 CODES AND STANDARDS :

2.1 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, Low Voltage Switchgear
4&5)
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

rotating electrical machinery

EN 50018 Electrical Apparatus for Potentially Explosive

Atmosphere [EEx(d)]

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

3.0 GENERAL REQUIREMENTS :

3.1 The offered equipment shall be brand new with state of the art technology and a
proven field track record. No prototype equipment shall be offered.

3.2 Vendor shall ensure availability of spare parts and maintenance support services
for the offered equipment for at least 15 years from the date of supply.

3.3 The vendor shall be responsible for design, engineering and manufacturing of the
complete actuator to fully meet the intent and requirements of this specification
and attached data sheets.

4.0 TECHNICAL SPECIFICATIONS

Each MOV actuator shall include the motor, actuator unit, gears, position
indicators, limit switches, hand wheel, electrical starter and 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 worst operating and electrical power supply conditions.

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4.1 MOTOR:

4.1.1 The motor shall be 3-phase squirrel cage induction type unless specified
otherwise in the data sheet. It shall have totally enclosed non-ventilated
construction.

4.1.2 The motor shall be designed for valve actuator service with high starting torque
and shall be suitable for Direct on line starting. It shall be rated for S2-15 minute
duty and shall conform to IS 325 or equivalent international standards.

4.1.3 The motor shall be provided with Thermostat (s) / thermister(s) embedded in the
hot spots of motor winding for protecting the motor.

4.1.4 The motor shall be suitable for operating the actuator at 75% of rated voltage at
motor terminals.

4.1.5 The motor shall have class „F‟ insulation with temperature rise limited to class „B‟
limits. Motor winding shall be treated to resist corrosive agents and moisture.

4.1.6 Motor rotor shall preferably be of die-cast aluminum and, if brazed, shall be free
from phosphorous.

4.2 INTEGRAL STARTER AND CONTROL TRANSFORMER :

The reversing starter, control transformer and local controls shall be integral with
the valve actuator, unless specified otherwise in the date sheet. Solid state
control of valve actuator and electrically isolated interface for remote control
requirement shall be provided, wherever these features exist in manufacturer‟s
design.

The integral starter shall be supplied with the following devices:

a) Electrically and mechanically interlocked revering contactors for opening

and closing operations.
b) Control transformer with necessary tappings and protected with suitable
easily replaceable fuses.
c) Terminal block for external cable connection fully prewired for internal
devices of valve actuator.
d) MOV actuators operating with AC power supply shall be provided with
Instantaneous Phase reversal protection.

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4.3 INTEGRAL PUSH BUTTON, SELECTOR AND CONTROL DEVICES :

The following local control devices shall be provided integral with the MOV
actuator:

a) Push buttons for “Opening/ Closing/ Stop” or alternatively “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.

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.

4.4 TORQUE AND TRAVEL LIMIT SWITCHES :

Torque limit switches shall be provided to protect the motor from over-loading by
cutting-off the power supply to motor during opening and closing operations. The
limit switches shall be preset. However, it shall be possible to set the value of
maximum torque during closing from 50% to 100% of rated torque of actuators.
Travel limit switch shall be provided to cut-off the power supply to the motor at
the end of preset limit of valve travel. 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 smoke of actuator may be provided, wherever this feature exists in
manufacturer‟s design.

4.5 CONTROL FACILITIES:

The internal controls and monitoring circuits shall be incorporated within the
integral starter along with transformer and control unit of valve actuator.
Following remote control and monitoring facilities are to be provided as a
minimum:

_ MOV open command

_ MOV close command
_ MOV open status indication
_ MOV close status indication
_ Position status of Remote / Local / Off selector switch

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Remote control facility shall be provided for all the actuators. The remote control
circuits shall be powered from internally derived control supply voltage. In order
to cater to remote control and indication requirements for „Position of Remote /
Local / Off selector switch‟, an additional Monitoring relay/ auxiliary relays shall
be provided as a part of the valve actuator. As an alternative, a common status
contact indicating the availability of the MOV actuator for remote control may be
provided by monitoring 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'
- Motor thermostat tripped
- Any other local fault / abnormal condition.

4.6 Hand Operation:

A hand wheel with hand‟ auto lockable lever shall be provided for emergency
operation of the MOV. The energisation of the motor shall automatically re-
engage power operation.

4.7 Two wire control System :

MOV actuators shall be suitable for 2-wire control system. These actuators shall
have general purpose FCU card embedded for communicating with any make of
master station or the FCU shall also be compatible for direct communication on
open type international standard 2 wire serial communication protocols/ modbus
for serial communication directly. Individual field units connectable to a master
station through a single 2-core cable loop for control and monitoring of the MOVs
Bidders shall provide open communication protocol (eg. MODBUS RTU,
FIELDBUS etc ;) for 2 wire connectivity. Bidders are required to interface their 2-
wire control systems with owner supplied PLCs (provided with corresponding
protocol interface card) as applicable. Each field unit / MOV actuator shall be
addressable through a unique address code. All the diagnostics & control
features required as per these specifications shall be available through 2 wire
system

4.8 REMOTE POSITION INDICATOR:

If requirement of remote position indication is specified in the data sheet, a 4-20

mA remote position transmitter shall be provided in the valve actuator and a
continuous position indicator for mounting in purchaser‟s remote panel shall be

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 DOUBLE BLOCK & BLEED AND DOUBLE
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supplied as a loose item. The remote position indicator shall continuously

indicate the position of travel of the valve.

4.9 NAMEPLATE:

Each motorized valve actuator shall be provided with a stainless steel nameplate
furnishing the following details, attached firmly to it at a place convenient for
reading:

a) Actuator tag number as per data sheet

b) Motor kW rating, motor time rating, motor supply voltage, nominal motor
phase current, auxiliary switch rating
c) Maximum torque setting
d) Actuator enclosure type, lubricant type
e) Actuator type, wiring diagram number/ catalogue number, actuator serial
number
A separate nameplate shall be provided for hazardous area application.

4.10 The enclosure of complete MOV actuator including motor, integral starter, control
transformer unit and all control devices shall have minimum IP-65 degree of
ingress protection.

4.11 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 MOV
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.

4.12 Vendor shall be solely responsible for the compatibility of the MOV actuator with
the valve and for the selection and sizing of various electrical devices and
components in the actuator.

4.13 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

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control systems for MOVs. 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.

5.0 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.

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 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.

5.2 Apart from the nameplate indicating the Tag NO. 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.

6.0 INSPECTION, TESTING AND ACCEPTANCE :

6.1 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

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assess the progress of work and the manufacturer shall render him all possible
assistance to do so.

6.2 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.

6.2.1 ROUTINE TEST : Functional and calibration test for torque and limit switches

6.2.2 ACCEPTANCE TESTS :

 Response time test

 Variation of supply voltage

 Variation of frequency

 Tests for motor (As per relevant IS/ IEC)

 Life test

 Test on output shaft

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 MOV actuators. Type
test certificates shall be furnished with bids. Final acceptance of MOVs at site
shall be subject to successful testing of the MOV actuators with the valves.

6.3 Type test certificates, original drawings referred in certificates and statutory
approval certificates and BIS license, where applicable, shall be shown to the

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inspection agency on demand. The certificates and BIS license must be valid at the
time of dispatch.

6.4 Test certificates of bought-out components shall be shown to the inspection

agency on demand.

7 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.

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. A 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.

8 SPARES & SPECIAL TOOLS :

8.1 Vendor shall submit list of standard spares of Actuators along with unit
rates with validity for 2 years.

8.2 Vendor shall submit list of special tools, if required for maintenance of Actuators
along with unit rates with validity of 2 years.

9 COMMISSIONING ASSISTANCE :

Vendor shall arrange to depute his commissioning engineer to each locations of

IOCL/BPCL/HPCL 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.

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10 WARRANTIES :

10.1 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
subject to not exceeding 24 months from date of dispatch.

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11.0 DATE SHEET FOR MOV ACTUATOR : PURCHASERS DATA

1.0 SITE CONDITIONS

S.NO.
1.1 Altitude Less than 1000 m Above MSL
1.2 Design ambient -10 deg. To + 55 deg. C
temperature
1.3 Humidity max. 100 %
1.4 MOV Tag Nos Will be intimated after award of contract.

2.0 SYSTEM CONDITIONS :

S.NO.
2.1 Supply Voltage 415V+ 10%, 3-phase AC for MOV
2.2 Supply 50 Hz + 3%
Frequency
2.3 System Earthing Solidly Earthed

3.0 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 Whether ―K-Mass‖ type or : No
equivalent fire proofing required
3.7.1 For MOV 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
a. Fully open and fully closed : Yes.
b. Partially open and partially closed : No
Control Requirement : Local & Remote for all
MOVs
Local / Remote / Off selector switch on : Required
MOV Actuator
Compatibility for interfacing with 2 wire : Required
control system

36
 DOUBLE BLOCK & BLEED AND DOUBLE
ISOLATION VALVES

Setting adjustable parameters of Actuator : From field & remote

( for 2 wire control system) thru Master Control
Station / PLC for 2 wire
control
Continuous position indication

Local Mechanical / LCD

indication is required.
Remote – Potentiometer / transducer for Required in control room
remote continuous indication 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 Position Required
For remote indication or position of Local Required
/ Remote selector switch
For availability of MOV actuator Remote Required
Operation ( contact from monitoring relay)
For indicating valve position in progress Not required
Remote emergency stop push button for Required.
Stopping Actuator
DCS/PLC interface for Remote Control / Remote Indication
Indication required for all MOVs
time of operation
- Opening 90 sec or as per design
of valve
- Closing 90 sec or as per design
of valve
Make of MOV Actuator Rotork,Auma or
Limitorque
Double Compression Glands & plugs ( for Flame and weather
unused entries ) , to be supplied with the Proof
Actuator
Test and Approval Certificates for Flame Proof Actuators
For Indigenous make MOV Refer technical specifications of
Actuators Electrical MOV Actuators
For Imported make MOV Refer technical specifications of
Actuators Electrical MOV Actuators
Submission of Type Test Yes
Certificates -

37
 DOUBLE BLOCK & BLEED AND DOUBLE
ISOLATION VALVES

Notes :

1. N.A. denotes “ Not Applicable.”

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. Two separate earthing bosses shall be provided in each actuator. All the
actuators shall be controlled through 2 wire control station. The Master station , if
available with the owner, the new actuators shall be hooked to the existing
Master station. Vendor to quote rates including Internal Field Control Unit (IFCU)
for actuators suitable for 2 wire control system. Supply of master station is not
in the scope of this tender.

4. 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.

5. Vendor shall furnish complete data as per Part-II of this data sheet for each MOV
Actuator along with the offer.

6. Remote Input signals for opening / closing / stopping the MOV 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.

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 DOUBLE BLOCK & BLEED AND DOUBLE
ISOLATION VALVES

12.0 Vendor data requirement MOV Actuator

S.No. Description With Bids Post order Final

Documents
For For Ref./
Review Records
1 Vendor Drawing / Document * *
Submission Schedule
2 List of deviations, if any, to MR
requirements
3 Data Sheets (duly filled in * * *
4 G.A and mounting details of actuators * *
5 Wiring and Connection diagrams * *
6 QA Plan of Vendor * *
7 Shop Inspection Plan and 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.

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 DOUBLE BLOCK & BLEED AND DOUBLE
ISOLATION VALVES

QAP for DBB VALVES SCOPE OF

INSPECTION
S. STAGE/ COMPONENT METHOD QUANTUM REFERENCE ACCEPTANCE RECORD SUB V TPI
No. Activity OF OF DOCUMENTS NORMS VEN E
CHECK CHECK DOR N
CHARACTERISTICS D
O
R
1. Incoming Raw material Surface Quality Visual As per Mfg As per Mfg Test As per Mfg Test Inspection W W R
raw for fabrication Test plan and plan and plan and Report
Materials / of valve body, applicable applicable code applicable code
components plate, flange code
etc
2. do do Dimensions Measurement As per Mfg Approved Approved Inspection W W R
Plan Drawing Drawing Report

3. do do Chemical & Mech. Review of All Heats As per relevant As per relevant Inspection W W R
Prop.( Hardness, Vendor Material Material Report
bend, Tensile etc.) TC Spec Spec Vendor
TC
4. WPS and As per As per
WPQ QAP applicable code applicable code
/specification /specification
5. Welding of Valve body Weld joint fit-up Visual 10% of qty. as As per As per W W R
valve body, per data sheet applicable code applicable code
bottom plate (wherever /specification /specification
& flanges applicable)
6. do do Radiography Visual 10% of qty. as As per As per W W R
per data sheet applicable code applicable code
(wherever /specification /specification
applicable)
7. do do Ultrasonic Visual 10% of qty. as As per As per UT Scan W R R
Examination per data sheet applicable code applicable code Report
(wherever /specification /specification
applicable)
8. Bought Out, Stems, Surface Defects Visual As per Mfg. App DWG / App DWG / Inspection W R R
Finished & Gaskets Sampling Relevant Std. Relevant Std. Report
Sub contract Gear units, Plan
items Fasteners etc

40
 DOUBLE BLOCK & BLEED AND DOUBLE
ISOLATION VALVES

9. Bought Out, Stems, Dimensions Measurement As per Mfg. App DWG / App DWG / Inspection W R R
Finished & Gaskets Sampling Relevant Std. Relevant Std. Report
Sub contract Gear units, Plan
items Fasteners etc
10. do do Physical and Review of TC As per Mfg. App DWG / App DWG / Inspection W R R
chemical properties of supplier Sampling Relevant Std. Relevant Std. Report
Plan
11. do thermal relief Hydro-test of Review of TC As per Mfg. App DWG / App DWG / Inspection W R R
valve of supplier Sampling Relevant Std. Relevant Std. Report
(100% ) Plan
12. Product Finished Hydrostatic shell 100 % of the As per As per As per Test - W R
Evaluation & Valve test valves of all applicable applicable code applicable code Report
Testing sizes & types code /specification /specification
/specification
/app drawing
13. do do Hydrostatic seat 100 % of the do As per As per Test - W W
test valves of all applicable code applicable code Report
sizes & types /specification /specification
14. do do Additional seat test 10 % of the do As per As per Test - W W
valves of all applicable code applicable code Report
sizes & types /specification /specification
15. do do Anti-static testing 5 % of the do As per As per Test - W R
valves of applicable code applicable code Report
each size & /specification /specification
type
16. do do Torque/thrust 1 % of the do As per As per Test - W R
functional testing valves of applicable code applicable code Report
each size & /specification /specification
type
17. do do Drive train strength 1 % of the do As per As per Test - W R
test valves of applicable code applicable code Report
each size & /specification /specification
type
18. do do Fire Safe testing As per As per As per As per Test - W R
applicable applicable applicable code applicable code Report
specification code /specification /specification
/specification /app drawing /app drawing
/app drawing

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 DOUBLE BLOCK & BLEED AND DOUBLE
ISOLATION VALVES

19. Product Finished Functional/ As per DWG. 100% App DWG App DWG Test ------ W H
Evaluation & Valve Operational Report
Testing Test (For Motor
/Actuator
Operated)
20. Final Finished Visual (TC Visual & Visual App DWG App DWG Inspection ------ W H
Inspection Valve Verification, SL. Std. 100% and Report
No. Marketing Measuring dimensions at
Flange finish, Tag Instruments random
No.) Bevel DP & MPI
Dimensions & Of bevel
Special Surfaces
Requirement in PO
21. Packing Finished ------ At random ----- As per dispatch App DWG & ---- ------- W R
Valve instructions Spec
22. 1Strip Check, Finished Valve Verify Components Visual 1 Valve per App DWG / PR App DWG & Inspection --- N NA
5Differential Type/Size & Spec Report A
hardness order
(see notes)

Legends: H-Hold (Offer for Witness & obtain clearance),W-Witness, R-Review, 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 specification, purchase specification 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 Specification

 WPQ - Welders Performance Qualification
 QAP - Quality assurance plan
 Manufacturing – Mgf
 Specification – Spec
 App DWG - Approved Drawing
 TC – Test Certificate

Note: This QAP is to be further developed by Vendor in line with the tender specifications, applicable codes & standards and to submit for owner’s approval before
manufacturing

42
Tender: Global Tender (Ref DBBV BPCL) for procurement of approx 86 nos. of Double Block & Bleed and Double Isolation Gate / Plug Valves
conforming to API 6D.
Tender Ref No: DBBV BPCL
System No: 10432

S.No Technical Queries on Electric Actuators Vendor Response

1. Please find attached the Electric Actuator Sizing Sheet (as
Annexure-1).
Bidder to furnish the data as asked in the Sizing sheet.

It is to be noted that the offered actuators are not designed

in accordance with the following parameters specified in
tender specifications:
• Max. pressure differential as 10.5 Kg/Cm2 across the
valve is to be considered for Valve Brakeaway torque
calculations for the following scenarios -
o Fully open position to fully close position at
max. flow rate.
o Fully close position to fully open position.
• Factor of Safety as 2 times of maximum valve
brakeaway torque.
2. Bidder to submit, Make / Model No. of the selected Electric
Actuators along with its de-codification sheet as per the
sizing sheet.
3. Bidder to furnish PESO / CCOE / CMRI certificate for
flameproof enclosure (valid as on date).
• For Electric Actuators
• For Limit Switches
4. Bidder to submit valid weatherproof certificate (min IP-65)
for the offered make of electric actuators.
5. Bidder to submit their deviation / compliance statement as
against tender specifications for the Electric Actuators.
6. Bidder to confirm following-
• availability of in-built position transmitter with LCD
display in the actuator.
• Availability of MODBUS RTU communication at
actuator
• Availability of hardwired contacts (potential Free)
for Open/ close/ remote-Local status of DBBV.
• ESD Port at Actuator.
7. Bidder to confirm that the manual handwheel provided at

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Tender: Global Tender (Ref DBBV BPCL) for procurement of approx 86 nos. of Double Block & Bleed and Double Isolation Gate / Plug Valves
conforming to API 6D.
Tender Ref No: DBBV BPCL
System No: 10432

S.No Technical Queries on Electric Actuators Vendor Response

actuator shall meet the torque requirement as 360 N (80
lbf). In this regard bidder to confirm clause 4.6 “Hand
Operation” of tender specifications for electric actuators.
8. Bidder to confirm that 2 separate earthing bosses are
provided in each actuator.
9. As per clause 8 “Spares & Special Tools” of tender
specifications for electric actuators, bidder to furnish
details/ list (only) of standard spares and special tools
required.

Tender: Global Tender (Ref. DBBV BPCL) for procurement of approx 86 nos. of Double Block & Bleed and Double Isolation Gate / Plug Valves conforming to API 6D.
Tender No: DBBV BPCL
System No: 10432

ANNEXURE-1 Electric Actuator Sizing Sheet

Valve Actual
Opening
Brakeaway Valve I/P
Valve Gear Actuator Max. / Closing Actuator KW
torque * Brake Gear Number of Mechnical torque at
Catalogue Box Make / Torque * RPM Time Rating
Valve (Nm) Factor of Away Ratio Revolutions advantage Gear
Sl. Valve No. Model* Model * (Nm) (Sec) (KW)
Size (See Note Safety torque Box
no Class
(Inch) 1 Below) (FOS) with (N-m)
FOS
Vendor to Vendor to (N-m) Vendor Vendor
Vendor to Vendor to
Vendor
Vendor to Vendor to
Vendor Vendor
Vendor to
to to to to to
Specify Specify Specify Specify Specify Specify Specify
Specify Specify Specify Specify Specify
1 6 150 2.0
2 8 150 2.0
3 10 150 2.0

Note 1:Max. pressure differential as 10.5 Kg/Cm2 across the valve is to be considered for Valve Brakeaway torque calculations for the
following scenarios -
(a) Fully open position to fully close position at max. flow rate.
(b) Fully close position to fully open position.

* Bidders to submit documentary evidence for the same.

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