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KUWAIT OIL COMPANY (K.S.C.)
STANDARDS PUBLICATION
KOCSTANDARD
FOR
VALVES: PART 1-BALL VALVES
DOC. NO. KOC-MP-033 Pt. 1
STANDARDS TEAM
DOC. NO. KOCMP-033 PART 1 Page 1 of 37 REV. 1
STANDARDS PUBLICATION
KOC STANDARD
FOR
VALVES:PART1-BALLVALVES
DOC. NO. KOC-MP-033 PART 1
STANDARDS TEAM
DOC. NO. KOC-MP-033 PART 1 Page 2 of 37 REV. 1
KOC STANDARD
FOR
VALVES: PART 1 - BALL VALVES
1 31.03.09
DOC. NO. KOC-MP-033 PART 1
(SUPERSEDES KOC- M- 012, REV. 2)
ISSUING AUTHORITY:
STANDARDS TEAM
Issued as Final
KOC Standard
Task Foroe 1111 A\A . .,:.A
(J"F.MP/14) ~
Page 3 of 37 REV. 1 DOC. NO. KOC-MP-033 PART 1 r
~ - - - - - - - - - - - - - - - - - - - - ~ - - - - - - - - - - - - - - - - ~ - - - - - - - - - - - - - - - - - - - - -
TABLE OF CONTENTS
FOREWORD
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
SCOPE
APPLICATION
TERMINOLOGY
3.1 Definitions
3.2 Abbreviations
REFERENCE STANDARDS, CODES AND SPECIFICATIONS
4.1 Conflicts
4.2 List of Standards and Codes
ENVIRONMENTAL CONDITIONS
HEALTH, SAFETY AND ENVIRONMENT
TECHNICAL REQUIREMENTS
7.1 Valve Design/Engineering
7.2 Valve Body
7.3 Anti-Static Design
7.4 Valve Operation
7.5 Anti Blow-Out Stem
VALVE MATERIALS
8.1 Valve Body and Other Components
8.2 Valve Identification Plate
8.3 Valve Seals
8.4 Threaded Opening in Valve Body for Plugs
8.5 Carbon Contents of Welded Parts of Valve
8.6 Electroless Nickel Plating (ENP)
8.7 Flanged Ends of Ball Valves
INSPECTION ANI) TESTING
9.1 General Requirements
9.2 Shop Inspection
9.3 Foundry Qualification
9.4 Quality Plan
9.5 Vendor Pre-Inspection Meetings (VPIM)
9.6 Hydrostatic Testing
Page No.
5
6
6
7
7
8
9.
9
9
12
12
13
13
14
15
15
16
16
16
16
16
17
17
17
17
18
18
18
19
19
20
20
DOC. NO. KOC-MP-033 PART 1 Page4of37 REV. 1
9.7 Valve Closure or Tightness Test 21
9.8 Nondestructive Examination 21
9i9 Hardness Testing 23
9.10 Examination Required-Socket Welding-end Valves 24
9.11 Positive Material Identification (PMI) 24
10.0 VALVE IDENTIFICATION
11.0 HANDLING, STORAGE AND CARE
11.1 Valve Handling
11.2 Valve Storage and Care
12.0 GUARANTEE & WARRANTY
12.1 Material, Valve Parts, and Valve Assembly
13.0 QUALITY ASSURANCE
14:0
15.0 DOCUMENTATION
15.1 General
15,2 Deliverables
16.0 SPARE PARTS AND MAINTENANCE DATA
APPENDICES:
",--' .. , -
APPENDIX-I ILLUSTRATION SHOWING TYPICAL API 60
TYPE "DOUBLE ISOLATION-BLEED"
,
(DIB) VALVE
APPENDIX-II KOC DATA SHEET FOR BALL VALVES
APPENDIX-III INDICATIVE INSPECTION & TEST PLAN FOR
BALL VALVES
APPENDIX-IV RECOMMENDED MATERIAL FOR BALL
VALVE COMPONENTS - ACCORDING
TO FLUID/SERVICE
ACKNOWLEDGEMENT
24
25
25
25
25
25
26
26
26
26
27
27
2835
28
29-30
31-33
34-35
36
D V
DOC. NO. KOC-MP-033 PART 1 Page 50f37 REV. 1
FOREWORD
This document "KOC Standard for Valves Part 1: Ball Valves (KOC-MP-033 Part
1)" is intended to provide basic technical requirements for Design, Materials, and
Inspection & Testing of Ball Valves intended for GC's, BS's, Tank farm, Water
Injection Plants, Pipelines, and other KOC onshore plants and facilities.
The Part 1 of this series of document (KOC-MP-033) covers "Ball Valves". Other
types such as gate, globe, check and butterfly valves are covered in subsequent
Parts under the same document number. This KOC Standard supplements the
requirements of API 60 IIS014313, ASME B16.34, ISO 17292, MSS SP-72, and
MSS SP-11 0 as applicable.
This Standard has been approved by the Standards Team, in consultation with the
Standards Technical Committee (STC) for consistent use throughout the corporate
engineering and operational facilities of Kuwait Oil
This Standard sets out to achieve the following objectives:
)- To specify the minimum technical requirements for Design, Material of
Construction-of- Ball-Valves- that-has- vast- and- significant application in KOC
facilities and installations, with a view to achieve quality, reliability, efficiency &
performance with cost effective approach.
)- To establish the necessary aspects of Inspection and Testing reqUirements of
Ball Valves so as to minimize the need for technical clarifications and disputes.
)- To maintain the KOC requirements of safety, protection, and integrity of KOC
piping, plant & equipment, personnel and environment as established by KOC
Fire and Safety Regulations, and Health, Safety and Environment Management
System (HSEMS) and HSE Policy.
)0 To augment comprehensively all aspects of design, construction, and testing
necessarily required by Kuwait Oil Company.
Feedback, comments or suggestions, derived from the application of this Standard at
any stage of design, construction, selection, purchase, field installation. operation,
and maintenance are encouraged, and should be directed to:
,
The Team Leader Standards
(Chairman, Standards Technical Committee)
Industrial Services Group, KOC
P. O. Box 9758, Ahmadi 61008, State of Kuwait
Task Force Responsible for This Standard
The Standards Technical Committee (STC) has entrusted the preparation of this
Standard to the Task Force No. (TF-MP/14) conSisting of the following:
Mr. Mohsin Mirza
Mr. H. Reddy
Mr. K. Subramanian
Mr. Ashish Kumar
Standards Team
I & C Team (N&W)
I & C Team (S&E)
Design Team
TF Leader & Author
Member
Member
Member
Ex: 61371
Ex: 61479
Ex: 61574
Ex: 61768
r /"',.
DOC. NO. KOC-MP-033 PART 11 Page 6 of 37 REV. 1
1.0 SCOPE
1.1 This standard specifies the basic technical requirements for "Design. Material,
Manufacture, Inspection, Testing, and Marking of Ball Valves for use throughout
KOC facilities and installations.
1.2 Ball Valve sizes, class, material and applicable standard(s) are as follows:
S. No.
1.
VALVE SIZE CLASS
# 150
NPS % to NPS 1 % # 300
#600
(See Note-I, & 2)
#800
#900
# 1500
#2500
MATERIAL
CS, ASS, OSS, Ni-Alloy
& High-Alloyed ASS
Bronze
# 150 CS, ASS, OSS, Ni-Alloy
APPLICABLE
STANDARD
(See Note 3)
BS EN ISO 17292
MSSSP 110
API 60 IIS014313
# 300 & High-Alloyed ASS
---- -- - -----2 ----. --- NeS_2and _OveL __ --_,. 60Q ---- I - - - = ~ = ~ .. . -=-- = = - - - = - - - ~ - + = ~ - = - - = .... ~ - = - - ~ ~ ~ - I - - -
. (See Note-I, & 2) # 900
Note-I:
# 1500
#2500
Ni-AI-Bronze ASME B 16.34
For selection of appropriate valve-ends (socket/threaded/flanged ends) refer to Piping Material Classes
o lS-LH-I 00 1. However KOC Standard for Piping Material Classes KOC-MP-O lOis under preparation
and will supersede/replace OlS-LH-IOOI when published. In the meantime, however 01 5-LH-100 1 will
remain active/effective.
Note-2:
Class 800 valves covered here are socket welded I threaded type only and of reduced bore.
Note-3:
BaH valves intended for potable water service shall be in accordance with Standard A WW A C507.
1.3 Project.Specific requirements not covered in this Standard shall be specified by
the controlling/concerned KOC Team in the Data sheet or Purchase Order
and/or Contract SpeCification, as applicable.
2.0 APPLICATION
2.1 Ball valves should not be used where the fluid/service is entrained with sand
particles.
2.2 These valves can be used in plant piping, pipelines, pressure vessels, heat
exchangers, storage tanks, rotating equipment and other stationary equipment
intended for process and utility services such as sweet and sour hydrocarbons
(oil/condensate/gas), plant air, instrument air, non-potable water such as fire
water, brackish water, produced water, effluent water etc. and compatible
chemicals as applicable.
)y
DOC. NO. KOC-MP-033 PART 1 Page 7 of 37
I
REV. 1
2.3 Any exceptions or deviations from this Standard, along with their merits and
justifications, shall be brought to the attention of KOC Controlling Team for their
review, consideration and amendment by Standards Team (if required).
2.4 Compliance with this standard does not in itself confer immunity from legal or
statutory obligations.
2.5 Valve actuators are not covered in this standard. Actuators, if provided, shall be
in accordance with KOC Standard for Motor Operated Valve Actuators KOC-E-
013.
3.0 TERMINOLOGY
3.1 Definitions
For the purpose of this Standard the following definitions shall apply.
3.1.1 Anti-static design:
Design such that it ensures electrical continuity throughout t_he valve
body. ball and its stem.' -
3.1.2 Company:
The Kuwait Oil Company
3.1.3 Controlling Team:
Any KOC Team authorized to initiate a request for procurement of material
and/or equipment for a KOC project, or any KOC Team that manages and/or
controls and/or executes a KOC project.
3.1.4 Double-Block- and-Bleed-Valve (DBB)
Single valve with two seating surfaces that, in the closed position, provides a
seal against pressure from both ends of the valve with a means of
venting/bleeding the cavity between the seating surfaces. (Refer to ISO 14313) .
. 3.1.5 Double-Isolation-and-Bleed-Valve (DIB)
Single valve with two seating surfaces, each of which, in the closed position,
provides a seal against pressure from a single source, with a means of
venting/bleeding the cavity between the seating surfaces. Refer to ISO 14313.
(For sketch/details see Appendix-I of this Standard).
3.1.6 Non-Sour Service or General Service:
The service involving water such as potable water, brackish water, fire water,
plant air, Instrument air etc. except the hydrocarbons, and fluids / chemicals that
contain H2S, Chlorides and other acidic properties. It should be noted that
waste / effluent water, in case has H2S, then, it should not be considered as
general service.
DOC. NO. KOC-MP-033 PART 1 Page 8 of 37 REV. 1
3.1.7 Progressive Examination:
In case of random examination, when repairs are found necessary as a result of
specific examination, then two additional items shall be examined. If either of
these proves to be defective, all similar items shall have to be examined.
3.1.8 Sour Service:
The fluid. services or exposure to oil field environment that contain hydrogen
sulphide (H2S) and that can cause cracking of materials (HIC / HSC / SCC/
SOHIC / SWC / SSC / SZC etc.) by some complex mechanism if the materials
used are not in accordance with NACE MR0175/1S015156.
3.1.9 Valve Body:
The valve body is the "shell" that holds the service/fluid pressure, with ends
intended for connection to piping /equipment. The valve body does not include
components such as the ball, seats, seals and other internal parts of the valve
that come in contract with the service fluid .
. . - - ~ - - - . - . - - . - - ~ . - - - - - - - - - . - - - - ~ - - . - . - ... -.. -- -...
3.1.10 Valve Trim:
The functional parts of a valve .that are exposed to the line fluid, usually refer to
the stem, closure member, and seating surfaces.
3.2 Abbreviations
ASS
CS
DSS
DBB
DIB
HIC
HSC
HR
HSE
HSEIMS
HSEMS
KOC
MAWP
MOP
NPS
OSHA
SCC
SOHle
SSC
SWC
SZC
Austenitic Stainless Steel
Carbon Steel
Duplex Stainless Steel
Double-Block-and-Bleed
Double-Isolation-and-Bleed-Valve
Hydrogen Induced Cracking
Hydrogen Stress Cracking
Rockwell Hardness
Health, Safety and Environment
Health, Safety & Environment Integrity Management System
Health, Safety & Environment Management System
Kuwait Oil Company
Maximum Allowable Working Pressure
Maximum Operating Pressure
Nominal Pipe Size
Occupational Safety and Health Administration
Stress Corrosion Cracking
Stress Oriented Hydrogen Induced Cracking
Sulfide Stress Cracking
Stepwise Cracking
Soft Zone Cracking
DOC. NO. KOC-MP-033 PART 1 I Page 9 of 37 REV. 1
4.0 REFERENCE STANDARDS, CODES AND SPECIFICATIONS
4.1 Conflicts
In the event of a conflict between this Standard and other KOC Standards or
applicable codes referenced herein, or purchase or contractual requirements,
or data sheets, the KOC (company) shall be notified of that deviation for a
resolution. However the order of precedence in the case of a conflict shall be
generally as follows without prejudice to the Contractual Order of Precedence
a) Kuwait Govt. Rules
b) Data Sheet and project specific contractual requirements
c) This KOC standard (KOC-MP-033 Part 1)
d) Other KOC standards (Which in the opinion of the Superintendent of the
Project/Contract are relevant to this Standard.)
e) Applicable international codes or standards
4.2 List of Standards and Codes
The--'atesTeditlon-(afthe-time of signing the -contract) of the following standards,
codes and specifications shall apply:
4.2.1 National/International Standards
API6D /ISO 14313
API SPEC6FA
API 607 /IS010497-5
ASME 81.20.1
ASME 816.5
ASME 816.10
ASME 816.24
ASME 816.34
ASME 816.47
ASME 831.3
Petroleum and Natural Gas Industries-Pipeline
Transportation System-pipeline Valves
Specification for fire Test for Valves
Testing of Valves - Fire Type - Testing
Requirements
Pipe Threads, General Purpose (Inch)
Pipe Flanges and Flanged Fittings NPS %
Through NPS 24
Face-to-Face and End-to-End dimensions of
valves
Cast Copper Alloy Pipe Flanges and Flanged
Fittings
Valves - Flanged, Threaded and Welding End
Large Diameter Steel Flanges NPS 26 Through
NPS60
Process Piping
DOC. NO. KOC-MP.o33 PART 1
ASME 831.4
ASME B31.8
ASME B36.10
ASTM A105/A 105M
ASTM A182
ASTM A193
ASTM A194
ASTM A216/A216M
ASTM A 388/A 388M
ASTM B61
ASTM 8148
AWlVAC507
BS EN ISO 10497
BS EN ISO 17292
ISO 7
ISO 261
Page 10 of 37 REV. 1
Pipeline Transportation Systems for Liquid
Hydrocarbons and other Liquids
Gas Transmission and Distribution Piping
Systems
Welded and Seamless Wrought Steel Pipe
Standard Specification for Carbon Steel
Forgings for Piping Applications
Standard Specification for Forged or Rolled
Alloy and Stainless Steel Pipe Flanges, Forged
Fittings and Valves and Parts for High-
Temperature Service
Standard Specification for Alloy-Steel and
Stainless Steel Bolting Materials for high
Temperature or High Pressure Service and
Other Special Purpose Applications. _
Standard Specification for Carbon and Alloy
Steel Nuts for Bolts for high Pressure or High
Temperature Service, or Both
Standard Specification for Steel Castings,
Carbon, Suitable for Fusion Welding, for High-
Temperature Service
Standard practice for ultrasonic examination of
heavy steel forgings
Standard SpeCification for Steam or Valve
Bronze Castings
Standard Specification for Aluminum-Bronze
Sand Castings
Ball Valves 6 in. Through 48 in. (150 mm
through 1200 mm)
Testing of valves-Fire type-testing reqUirements
Metal Ball Valves for Petroleum, Petrochemical
and Allied Industries
Pipe threads Where Pressure-Tight Joints are
made on the threads - Part 1 & 2
ISO General Purpose Metric Screw threads
DOC. NO. PART 1
ISO 9000
ISO 9001
MSS SP-55
MSS SP-72
MSS SP-110
Page 11 of 37 REV. 1
Quality Management Systems - Fundamentals
and Vocabulary
Quality Management Systems - Requirements
Quality Standard for Steel Castings for Valves,
Flanges, Fittings and Other Piping Components-
Visual method for Evaluation of Surface
Irregularities
Ball Valves with Flanged or Butt-Welding Ends
for General Service
Ball Valves Threaded, Socket-Welding, Solder
joint, Grooved and Flared Ends
NACE-MR0175/IS0 15156 Petroleum and Natural Gas Industries-Materials
Parts 1-3 for Use in H2S-Containing Environments in Oil
and Gas production
4.2.2 KOC Standards
KOC-E-013
KOC-G-004
KOC-Q-014
KOC I HSE Document
KOC Standard for Motor Operated Valve
Actuators
KOC Standard for Packing. Marking and
Documentation
KOC Standard for Project QA/QC Requirements
KOC Fire and Safety Regulations
4.2.3 015 Engineering Group Specifications
015-LH-1001
015-WH-1003
Piping Material Classes (See Note-l o/Clause 1.2)
Inspection of Castings for General Pressure
Service
DOC. NO. KOC-MP-033 PART 1 Page 12 of 37 REV. 1
5.0 ENVIRONMENTAL CONDITIONS
The environmental conditions in Kuwait are severe. Refer to "KOC Standard
for Basic Design Data" (KOC-G-007), which provides the basic information
required for design such as the temperature, wind, environmental, site and
utility supply conditions prevailing throughout the KOC facilities.
6.0 HEALTH. SAFETY AND ENVIRONMENT
All applicable safety requirements of Occupational Safety and Health
Administration-OSHA Standards shall be considered in the design, materials,
and manufacture of valve seals/gaskets covered in this standard. KOC
prohibits use of asbestos in its facilities and installations.
The Manufacturer/Contractor shall fully adhere to KOC Fire and Safety
Regulations, KOC HSEMS (HSE Management Systems) requirements, and
KOC HSEIMS (HSE Integrated Management Systems) requirements/
procedures/guidelines for protection of KOC personnel, equipment, property,
and environment etc where applicable.
DOC. NO. PART 1 I Page 13 of 37
I
REV. 1
7.0 TECHNICAL REQUIREMENTS
7.1 Valve Design/Engineering
7.1.1 Ball Valves shall be designed, manufactured, tested, and supplied in
accordance with clause 1.2 of this standard.
7.1.2 The type of valves shall be in accordance with the reqUirements of KOC Data
Sheets / Contract Specifications.
7.1.3 Unless otherwise specified in KOC Data Sheets/Contract SpeCifications the
ball valves furnished shall be of full bore and suitable for pigging when
applicable, except for class BOO valves (socket weld ends or threaded ends)
as per BS EN ISO 17292.
7.1.4 Unless otherwise specified in KOC Standard for Piping Material Classes KOC-
MP-010/015-LH-1001 (See Note-1 clause 1.2), KOC Data Sheets / Contract
SpeCification, the valve ends shall be as follows:
a) NPS % to NPS 1 %: Socket weld ends or Threaded ends or Flanged
ends.
b) NPS 2 and above: Flanged with RF ends conforming to ASME B 16.5 or
AMSE B 16.47 for class 150, 300, and 600, as applicable.
c) NPS 2 and above: Flanged with RT J ends conforming to ASME B 16.5 or
ASME B 16.47 for Class 900,1500, and 2500, as applicable.
7.1.5 The face-to-face and end-to-end dimensions of ball valves shall be as per the
applicable standard. However if the same is not specified in applicable valve
standard or KOC Data sheets, it shall be as per ASME 816.10.
7.1.6 Ball valves shall be either floating type or trunnion mounted for sizes NPS %
to NPS 3. However the ball valve sizes NPS 4 and over shall be trunnion
mounted as per applicable standard specified in Clause 1.2 of this Standard.
7.1.7 All valves above size NPS 2 shall be provided with greasing nipples as
mentioned below:
a) Drive/rotating mechanism and bonnet areas.
b) Seat holder area at each seat assembly (one grease nipple for sizes NPS
3 to NPS 6 and two grease nipples for sizes above NPS 6).
7.1.B The ball valve sizes NPS 2 and over shall be provided with necessary
openings (threaded holes) for drain/vent connections. The connection shall be
in accordance with API6D /IS014313/ASME B 16.34.
7.1.9 All valves sizes NPS 4 and above shall be provided with double block and
bleed (DBB) arrangement to check the valve integrity against
leakage/passing, when the valve is in closed condition. The
DOC. NO. KOC-MP-033 PART 1 Page 14 of 37 REV. 1
connections shall be fitted with threaded plugs preferably of NPS % on the top
of the valve body for gas service and at bottom for liquid service. The
threaded plug material shall satisfy NACE MR0175/IS015156 requirements.
7.1.10 In case the socket welded valves incorporate soft seats, the Manufacturer
Nendor shall supply those valves complete with pipe nipples (at least 150 mm
long) welded at each end of valve prior to valve assembly.
7.1.11 The ball valves shall conform to API 607 or ISO 10497 or API 6FA for Fire-
Test Design.
7.1.12 The lever/wrench and bonnet-cover shall be provided on all valves with
indicator to show the position of the ball port. Travel stops shall be provided
for both fully open and fully closed positions of the valve.
7.1.13 The ball valves intended for potable water service shall be in accordance with
Standard A\J\NVA C 507.
7.1.14 When the ball valves are intended for Double-Block-and-Bleed (DBB) or
...
that such valves adequately satisfy the requirements as defined under clause
3.0 of this Standard/API6D/IS014313 or otherwise as required by KOC.
7.2 Valve Body
7.2.1 The minimum body wall thickness shall be as specified in applicable standard.
In case of valves manufactured according to API 6DIISO 14313, the minimum
body wall thickness shall conform to ASME B16.34 requirements.
7.2.2 Body seat ring assemblies shall be designed so as to be replaceable except
for those valves having a one piece welded construction. Spring loaded seat
rings shall be provided for sizes NPS 3 and above except in single $eat
design. '
7.2.3 The valve seats shall be either metallic or non-metallic (or with elastomer
insert) as per the KOC Data Sheet. Refer Appendix-IV of this Standard.
7.2.4 In case of valve with metallic seat, a minimum hardness differential of 50. HB
shall be provided between ball and seat surface.
7.2.5 In case elastomer insert is used, seat shall be fabricated in such a way as to
ensure proper seal in case of damage or wear of elastomer material.
Secondary sealing arrangement shall be provided for sizes NPS 4 and above
by means of a sealant filling port through which sealant can be injected. Single
seat designs need no secondary sealing arrangement.
7.2.6 In case of valves manufactured to MSS SP-11 0, the Manufacturer shall submit
the design calculations in accordance with ASME Sec. VIII Div. 1 for Company
approval.
7.2.7 All valves shall be provided with lock-openllock-closed provision.
DOC. NO. KOC-MP-033 PART 1 Page 15 of 37 REV. 1
7.2.8 The ball valves shall be tight shut-off and closure tightness test shall be "as per
the applicable standard specified in Clause 1.2 of this Standard.
7.2.9 The adjustable packing glands of valves shall be easily accessible for
tightening the stem seals without disassembling either the valve itself or its
parts.
7.3 Anti-Static Design
7.3.1 Soft seated valves shall be provided with anti-static device to ensure electrical
continuity between ball, stem and valve body. Anti-static devices are not
necessarily required in valves designed for metal to metal contact provided
that the level of contact resistance does not exceed 10 ohm (on dry valve)
under any operating condition, using a 12 volt D.C. power source.
7.3.2 The Manufacturer shall submit to KOC an authentic and valid certificate
showing conformance and compliance with the above requirement.
7.4 Valve Operation
The valve manufacturer shall submit a duly completed data sheet conSidering
all the requirements of contract specifications and KOC Data Sheet for KOC
(company) review and approval. An indicative Data Sheet format is shown in
APPENDIX-II of this Standard. The ball valve operation mechanism shall be
as shown in the Table-1 below:
Table-1: VALVE OPERATION
2 600
3 900,1500 and 2500
3 (Inclusive) Over
Note-I: All actuated ball valves shall have an alternate mechanism to operate manually.
DOC. NO. KOC-MP-033 PART 1 Page 16 of 37 REV. 1
7.5 Anti-Blow-Out Stem
7.5.1 The valves shall be designed to ensure that during operation if a failure occurs
either at stem-ball connection, or at any other part of the stem within the
pressure boundary then no portion of the stem shall be ejected out.
7.5.2 The design shall ensure that while under operation, the valve stem shall not
eject when the valve external parts such as gland and gland flange bolting are
disassembled.
8.0 VALVE MATERIALS
All Materials used in the valves shall be brand new and of prime quality
conforming to the requirements of this Standard and the codes, standards,
and specifications referenced herein.
8.1 Valve Body and Other Componenl
QLappropriate material for various components of ball valve
shall be in accordance with the KOC Data Sheets / Contract Specifications,
KOC Standard for Piping Material Classes KOC-MP-010/015-LH-1001 (See
Note-1 of Clause 1.2) and Appendix-IV of this Standard.
8.1.2 In addition, the materials of valves intended for sour service shall conform to
the requirements of NACE MR0175/ISO 15156.
8.1.3 The Manufacturer shall strictly conform to the materials as specified in the
KOC Data Sheet. Manufacturer shall ensure that ASTM A-36 or any other
structural quality material shall not be used for any part(s) of the valve(s).
8.2
8.3
Valve Identification Plate
The material used for the identification plate shall be an austenitic stainless
steel or a nickel alloy. The identification plate shall be attached to the valve by
corrosion-resistant rivets.
Valve Seals
8.3.1 In case the stem seals, body seals, cover seals etc are non-metallic they shall
be suitable for the maximum design/allowable temperature, whichever is
higher, of the system.
8.3.2 Stem seals shall be such that they can be replaced while the valve is on-
stream for valves with block-and -bleed arrangement.
8.3.3 Provision shall be made for emergency stem sealing injection for valves size
NPS 4 and over. This arrangement shall be provided to restore the sealing
integrity if damage is caused to the sealing surface(s).
DOC. NO. KOC-MP-033 PART 1 Page 17 of 37 REV. 1
8.4 Threaded Opening in Valve Body for Plugs
8.4.1 Where the threaded plugs are intended in sour service, it shall be bleeding
type for safe release of leaked fluids to prevent any accidental damage to the
operator or as otherwise required by KOC.
8.4.2 When the valve is intended for sour service, the plug material shall meet the
requirements of NACE MROl75 /18015156. Normally threaded plugs are not
recommended in sour service, therefore the Manufacturer/Contractor should
suggest/propose a suitable alternative to KOC.
8.4.3 Malleable, grey or any other form of cast iron shall not be used for plugs.
8.5 Carbon Contents of Welded Parts of Valve
8.5.1 The carbon and manganese contents of all pressure-containing parts for
carbon steel materials involved in welding operations shall be restricted as
follows:
_. -' --',
a) C = 0.25 % (Max)
b) The Carbon Equivalent (CE) shall be 0.41 % max as specified below:
CE = C% + Mn%/6 +(Cr%+Mo%+V%)/5+(Ni%+Cu%)/15 = 0.41 % max.
8.5.2 For the alloy steels and stainless steels materials involved in welding, the
carbon content shall be limited to such a level to ensure good weldability.
8.6 Electro'ess Nickel Plating (ENP)
8.6.1 The carbon steel balls (for applicable sizes refer Note-1 of Appendix-II) shall
be plated with Electroless Nickel Plating (ENP) in accordance with ASTM B
733 8C 4, severe service, Type II or III phosphorus contents, and heat treated
to Class 1 or 2 as per A8TM B 733.
8.6.2 The ENP composition shall be: 10-12 % Phosphorus, 0.05% of unspecified
elements (max) and remainder as Nickel.
8.6.3 The ENP thickness shall be 76 jJm (min.)
8.6.4 The ENP shall be tested for the following: Appearance, Thickness, Adhesion,
Porosity (Ferroxyl Test). Hardness, Alloy composition, and Corrosion
resistance.
8.7 Flanged Ends of Ball Valves
8.7.1 Flanges of the flanged type ball valve size NP8 24 and under shall be as per
ASME B 16.5. and for size 26 and over shall be as per ASME B 16.47 series
'A' Type, unless otherwise specified/required by KOC.
DOC. NO. KOC-MP-033 PART 1 Page 18 of 37 REV. 1
9.0 INSPECTION AND TESTING
9.1 General Requirements
9.1.1 The manufacturer shall carry out inspection and testing as specified in this
Standard and in accordance with Company Approved inspection and Test
Plan (ITP).
9.1.2 The construction, quality of workmanship, the dimensions, inspection and
testing of ball valve shall be carried out in accordance with API 6D 118014313
or BS EN ISO 17292 or MSS SP-110 as applicable and this KOC Standard.
9.1.3 The testing of valve materials shall be carried out by the Manufacturer at his
own laboratories or at a laboratory internationally recognized and duly
accredited to international Standards.
9.1.4 The test certificate for fire safe design as per the applicable standard shall be
submitted to KOC for review and approval.
9.1.5 Manufacturing, Inspection & Testing of valves shall take place at KOCis
approved Manufacturer's facilities only.
9.1.6 Contractor or its authorized inspection agency shall inspect the materials in
accordance with the Inspection and Test Plans (ITP) prepared by the
Manufacturer and approved by the Company.
9.1.7 In addition, Company reserves the right to carry out the inspection (on its own
or appoint a third party to do so on its behalf or both) and examination of the
valves at the manufacturing facilities and testing laboratories in accordance
with the Company approved ITP.
9.1.8 All bought-out items (such as castings, forgings etc.) shall be inspected at the
sub-vendor's premises by the valve Manufacturer.
9.1.9 When random inspection is specified and if it fails to meet the requirements,
progressive inspection shall be carried out to the satisfaction of Company at
the cost of the manufacturer.
9.2 Shop Inspection
9.2.1 The manufacturer shall be responsible for all required QA/QC and inspection
work to satisfy the requirements of this Standard.
9.2.2 KOC may utilize the services of his inspectors or inspectors appointed by him
(KOC) to visit the Manufacturer's facilities to witness and verify the quality of
work, raw materials, finished products, production process and the equipment
used.
DOC. NO. KOC-MP-033 PART 1 Page 19 of 37 REV. 1
9.2.3 The KOC or inspectors appointed by KOC shall have free access to those
areas of the Manufacturer's facilities that are necessary to ensure that the
manufactured products comply with the requirements of this Standard and the
Standards referenced herein.
9.2.4 KOC (Company) inspectors shall have a minimum of two (2) weeks advance
notice, and shall be provided access to the Manufacturers shop(s) during
manufacturing, fabrication, assembly, inspection and testing of all components
I items of supplies covered by this standard.
9.3 Foundry Qualification
9.3.1 The foundry shop shall be fully accredited to ISO 9000 quality systems and
shall be amply capable to handle the size and weight of the required forgings
or castings.
9.3.2 When large order is placed the first pouring qualification shall be carried out
for each size and type of valve in presence of Company or its nominated
____________________ . _______________ . _________ . ___ _
9.3.3 If the first pouring is approved and qualified then further qualification of the
pouring shall not be required for other purchases from the same manufacturer
for the sizes and types of valves qualified.
9.3.4 The following are mandatory requirements for first pouring qualification:
- Chemical Composition
- Mechanical Properties
- Visual and dimensional inspection
- 100% RT shall be performed.
- 100 % MT I PT shall be performed accordingly
- Hardness Survey
9.4 Quality Plan
The valve Manufacturer shall prepare and submit a detailed quality plan for
Company approval. The quality plan shall consist of the following:
9.4.1 Manufacturing Plan
9.4.2 Inspection and Test Plan (lTP)
a) The Manufacturer shall prepare ITP in accordance with manufacturing
plan as per the contractual requirements and shall submit to Company for
approval.
b) Tentatively the ITP shall list the sequence of all inspection and testing
activities that shall be carried out by the Manufacturer, Contractor and
Company or their appointed third party inspection agencies. The plan
shall include manufacturing, fabrication, assembly, inspection and testing
and packing for shipment in a chronological order. showing the frequency p
DOC. NO. KOC-MP-033 PART 1 Page 20 of 37 REV. 1
9.4.3
9.4.4
9.4.5
9.4.6
9.5
9.5.1
9.5.2
9.5.3
9.6
of control, the acceptance limits, the governing code and whether a
document or report is produced for each activity.
c) An indicative ITP is attached in APPENDIX-III of this Standard for
guidance only to facilitate the Manufacturer about the outline of ITP
inspection activities. However, the extent of examination by Company &
Contractor shall be finalized on mutual agreement.
Inspection & Test Procedures
Valve Detailed drawings & Data Sheets
List of sub-vendors
Manufacturer's QA/QC organization chart
Vendor Pre-Inspection Meetings (VPIM)
The VPIM shall be conducted at Manufacturer's facility as per Company
Co"-tract Specification requirements.
The agenda for the VPIM shall be in accordance with the Company Contract
SpeCification / Company purchase order requirement and KOC-Q-014.
During the VPIM the vendor, contractor and company will review and finalize
the ITP and confirm the requirements for witnessing 0JV), surveillance (S),
monitoring (M), and reviewing (R) in the plan. The approved ITP shall be
strictly adhered to throughout the entire fabrication, assembly, inspection, and
testing period';
Hydrostatic Testing
Note: Test Certificates for each valve successfully passing the shell tests shall
be provided by Manufacturer/Contractor to KOC, documenting compliance of
tested valves with test requirements, including test pressure. Moreover when
the hydrostatic testing of new or existing piping or pipeline systems containing
ball valves is undertaken, it shall be ensured that all ball valves are in the full-
open position and the line test pressure shall not exceed the allowable
hydrostatic test pressure of valve body or shell.
9.6.1 General Requirements:
a)
b)
c)
The test fluid temperature shall be within the temperature range of 5 c
and 50C.
In case of carbon steel valves the test shall be carried out with fresh
water that may contain corrosion inhibitor, or with kerosene, or with other
suitable fluids provided the viscosity of such fluids is not greater than that
of water.
In case of stainless steel valves, the test shall be carried out with water
that shall not contain chlorides exceeding 30 ppm. ~
/'
DOC. NO. KOC-MP-033 PART 1 Page 21 of 37 REV. 1
9.6.2 Valves shall not be painted or otherwise coated with materials capable of
sealing against leakage before the valve body tests.
9.6.3 All gauges shall have a range such that the test pressure is within 30% to SO%
of the full range. The gauges shall have valid calibration certificate.
9.6.4 Body Hydrostatic Test
The body hydrostatic test shall be carried out in accordance with the
applicable valve standard.
9.7 Valve Closure or Tightness Test
9.7.1 The valve closure test shall be done in accordance with the applicable
standard.
9.7.2 In addition, low pressure closure test (supplementary test) shall be carried out
for valves conforming to API 60 liSa 14313. The low pressure closure test
shall beat a pressure 5 . ~ . b a r 0.7 bar.
9.8 Nondestructive Examination
9.S.1 Visual Examination
All valves shall be visually examined in accordance with MSS SP-55.
9.S.2 Valve Surface Examination
a) All exterior and all accessible interior surfaces of valve body and bonnet
shall undergo a surface examination.
b) Technique:
i) Magnetic Particle Testing shall used for all Ferromagnetic materials
as per ASME Sec V, Article 7.
ii) Penetrant Testing shall be done on all non-magnetic materials as
per ASME Sec V, Article 6.
c) Extent of Examination
100% Examination on all valves intended to be used in sour service.
100% Examination on all valves of Class 600 and over intended to be
used in non-sour service.
d) Acceptance Criteria
i) Acceptance criteria for of PT shall be in accordance with ASME
Sec VIII, Div 1, Appendix-S.
/'
DOC. NO. KOCMP-033 PART 1 Page 22 of 37
I
REV. 1
Ii) Acceptance criteria for MT shall be in accordance with ASME Sec
VIII, Oiv. 1 Appendix-6.
9.8.3 Radiography Examination
I. Butt Welds:
a) Technique:
RT (Radiographic Examination) as per ASME Sec V, Article 2.
b) Extent of Examination:
All butt welds shall be 100% examined.
c) Acceptance Criteria:
Radiographs shall be evaluated as per UW-51 of ASME Sec. VIII Div.1.
II. Cast Valves (Body and Bonnet):
a) Technique:
Examination of casting intended for valves shall be carried out in
accordance- -with- ASME Sec V, Article 2 and as specified in
supplementary NOE (Nondestructive Examination) requirement A.2 of
API 60.
i) The Coverage and location of radiographic examination shall be as
per ASME 816.34
Ii) UT in place of RT shall not be acceptable.
b) Extent of Examination:
a) All valves shall be 100% radiographed for sizes NPS 6 & above for
class 600 & above.
b) For all other classes for size NPS 6 and above, the examination
shall be on 20% of valves selected on random basis. The random
selection shall include all sizes and classes of valves on production
basis.
ii) Non-sour-service
10% of all valves selected on random basis shall be radiographed
for valve size NPS 6 and over. The random selection shall include
all sizes and classes of valves on production basis.
c) Acceptance Criteria:
i) ASME B16.34 Appendix I shall be used for acceptance criteria.
v
DOC. NO. KOC-MP-033 PART 1 Page 23 of 37 REV. 1
ii) In case of random examination, when repairs are found necessary
as a result of radiographic examination, then progressive
examination shall be followed.
9.8.4 Ultrasonic Examination of Forged Valves (Body and Bonnet):
a) Technique:
Examination of forgings intended for valves shall be carried out in
accordance with ASME Sec V, Article 5 and ASTM A388.
b) Extent of Examination:
c)
i) Sour-service
a) All forged bodies prior to proof machining shall be 100%
ultrasonically examined for sizes NPS 6 & above for class
600 & above.
b) For all other classes 'for size NPS 6 and above, tlie
examination shall be on 20% of valves selected on random
basis. The random selection shall include all sizes and
classes of valves on production basis.
ii) Non-sour-service
10% of all valves. selected on random basis shall be 100%
ultrasonically examined for valve size NPS 6 and over. The random
selection shall include all sizes and classes of valves on production
basis.
Acceptance Criteria:
i) Acceptance criteria shall be in accordance with Appendix IV-2.1 of
ASME B 16.34.
ii) In case of random examination, when repairs are found necessary
as a result of radiographic/ultrasonic examination, then progressive
examination shall be followed.
9.8.5 Defect Removal and Repair
i) Defect removal and repair shall meet the requirements of ASME
B16.34 Para 8.4.
ii) In case of castings, KOC specification 015-WH-1003 shall also apply.
iii) PWHT is mandatory for Ferritic steels intended for sour service.
9.9 Hardness Testing
9.9.1 All wetted parts of valves (and repair welds) intended for sour service shall be
hardness tested in accordance with NACE MR017511S015156.
DOC. NO. KOC-MP-033 PART 1 Page 24 of 37 REV. 1
9.9.2 Hardness Test shall be done on 10% of valves per heat selected on random
basis. The random selection shall include all sizes and classes of valves on
production basis. Valves not meeting the hardness requirements shall be
rejected and progressive examination shall be followed for the entire heat.
9.9.3 If the Hardness Testing reveals any points not meeting requirements,
additional testing shall be done as per the progressive examination.
9.10 Examination Required- Socket Welding-end Valves
9.10.1 This requirement is applicable to socket weld end valves to determine whether
the socket size is appropriate. It is recommended that a max clearance /gap
of 1.0 mm be provided.
9.10.2 Radiography shall be performed on random basis of 5% of socket welds to
find out the clearance/gap between the pipe nipple and of socket.
9.10.3 When incorrect gaps are found, additional radiography is required as per the
___ ..,. ___ ._ .. .._.. ._ .. _ .. _ __ ... _ ... _ ...
9.11 Positive Material Identification (PMI)
9.11.1 PMI shall be done on valves ma.de of corrosion resistant alloys. The extent of
examination shall be 10% of valves selected on random basis. The random
selection shall include all sizes and classes of valves on production basis. For
other details refer API RP 578: Material Verification Program where required.
9.11.2 The PMI results shall meet the applicable material specifications.
9.11.3 During random PMI, if the examination results do not conform to the material
specification, then progressive examination shall be followed.
10.0 VALVE IDENTIFICATION
10.1 Valve identification shall be in accordance with the applicable Standard.
10.2 In addition, the ball valves identification shall also fulfill the following
requirements:
10.2.1 Unique serial number for each valve shall be mentioned in the body and the
name plate of the valve.
10.2.2 Valve size and class shall be mentioned on the valve body by embossing or
punching (with round nose punch) for valve sizes NPS 3 and above.
10.2.3 Details of ball and seat materials shall also be included in the name plate
details.
10.2.4 Ball Valves intended for sour service shall be marked as "Comply NACE
MR0175I1S015156".
DOC. NO. KOCMP033 PART 1 Page 25 of 37 REV. 1
11.0 HANDLING. STORAGE AND CARE
11.1 Valve Handling
11.1.1 As soon as the valve testing is successfully completed, the flanges of the
flanged valves shall be covered with plywood or other protective devices (with
bolts) to avoid ingress of moisture or any foreign material inside the valves.
11.1.2 The valves are precision machined and manufactured to achieve a smooth
flange surface. It is therefore imperative and necessary that the valves should
be handled with care in order to avoid any scratch or dent or damage to the
flange surface.
11.1.3 It is recommended that the valves should be softly, carefully and correctly
handled, packed and transported to avoid any unnecessary jolts, hit, bump
and knock-down.
11.1.4
11.1.5
11.1.6
11.2
11.2.1
11.2.2
11.2.3
12.0
12.1
12.1.1
12.1.2
It should be ensured that the valve does not come in contact with any
. chemical or fluidjnofder to avoid it from injurious effects and corrosion.
Ball valves, especially larger sizes, should be stored and shipped in the full-
open position to prevent damage to the exterior surface of the ball.
Lifting lugs shall be provided on all valves size NPS 4 and above.
Valve Storage and Care
The valves shall be stored carefully in a clean and dry environment.
The valves shall be protected with plastic end caps to prevent ingress of
water, moisture, foreign material, dust, dirt etc and also to protect the flange
faces.
It is recommended that the valves should be stored in covered area to prevent
damaging effects of rain, dust, and weather.
GUARANTEE & WARRANTY
Material. Valve Parts. and Valve Assembly
Unless an exception is recorded by the Manufacturer I Supplier in his proposal
and is agreed and accepted by KOC (Company), it shall be understood that
the Manufacturer I Supplier agrees to the guarantee and warranties as per
clause 12.1.2 of this Standard.
All valve and its components shall be new and the valve shall be warranted by
the Manufacturer I Vendor I Contractor against defective and inferior quality
material, design, workmanship and is fit-for-the-purpose in accordance with
the requirements of Purchase order I Contract speCification.
DOC. NO. PART 1 Page 26 of 37 REV. 1
12.1.3 The Manufacturer I Supplier shall provide to KOC (Company) an affidavit
stating in clear terms that all supplied Ball Valves, its material, and its
components etc. are in accordance with the requirements of this Standard and
the codes and the standards referenced herein.
13.0 QUALITY ASSURANCE
The Manufacturer shall operate quality systems to ensure that the
requirements of this Standard are achieved. The quality systems shall be
based on ISO 9000 series of Standards or equivalent. The Manufacturer shall
demonstrate compliance by providing a copy of the accredited Certificate and
a copy their quality manual. Verification of Manufacturer's quality system is
normally part of the pre-qualification procedure and is, therefore, not detailed
in this Standard.
14.0 PACKING. MARKING ANI) DOCUMENTATION
14.1 Packing, marking, and shipping documentation shall comply with the
requirements of KOC Standard for lIPacking, Marking and Documentation"
___________________ .
14.2 The marking shall be as follows or otherwise as required by KOC:
a) Manufacturer's name and Trade Mark
b) Valve Body Material
c) Pressure Class, e.g. #150 or 300
d) Nominal Size e.g. NPS 12, or NPS 20
e) Valves that are intended for sour service shall be marked as "Comply
NACE MR0175/1S015156"
f) Any other supplementary reqUirements, deemed necessary
15.0 DOCUMENTATION
15.1 General
15.1.1 All correspondence, instructions, Data Sheets, drawings, calculations,
procedures or any other written information shall be in English language. In
case of dual languages, one language shall be English.
15.1.2 All dimensions, units of measurement, physical constants etc. shall be in SI
units, unless otherwise specified.
15.1.3 In addition to hard copies, all final documents such as speci'fications, Data
Sheets, drawings, procedures and inspection reports shall be provided in
electronic software formats (Latest versions of Microsoft Word, Excel, and
AutoCAD).
i .
DOC. NO. KOC-MP-033 PART 1 Page 27 of 37 REV. 1
15.2 Deliverables
15.2.1 The Manufacturer shall submit to Company for review and approval the
manufacturer's Record Book (MRB) with all certified valve test certificates, as-
built data sheets, as-built General Arrangement & Assembly Drawings,
procedures & inspection reports, spare parts details, Valve Brochures etc.
15.2.2 Valve unique serial number shall be mentioned in the valve test certificate.
16.0 SPARE PARTS & MAINTENANCE DATA
The Packager shall comply with the requirements of "KOC Standard for Spare
Parts and Maintenance Data" (KOC-G-009).
v
DOC. NO. KOC-MP-033 PART 1 Page 28 of 37 REV. 1
APPENDIX-1
ILLUSTRATION SHOWING TYPICAL API 60 TYPE
"DOUBLE- ISOLA TION-8LEED" (018) VALVE
Typioal Valve, Type - IIDI:B-1
11
Ve'nt Plug
\
\
\

<
DOC. NO. KOCMP-033 PART 1 Page 29 of 37 REV. 1
APPENDIXII
KOC DATA SHEET FOR BALL VALVES
DESIGN FEATURES:
S.No DESCRIPTION I MANUFACTURER'S PROPOSAL
1 DESIGN CODE
I
2 NOMINAL SIZE (Inch)
i
3 VALVE TYPE
4 VALVE OPERATION MECHANISM
i 5
DOUBLE BLOCK AND BLEED YES 0 N/A
0
6 VALVE ClASS/RATING
I
7 LOCK OPEN/LOCK CLOSED YES
0
N/A
0
8 ANTI BLOW-OUT STEM YES
0
N/A
0
SERVICE REQUIREMENTS:
9 SERVICE FLUID (LIQUID /GAS)
10 FLOW MEDIUM COMPOSITION
11 COMPLY NACE MR0175/IS015156 YES 0 N/A 0
12 CONTAMINANTS (IF ANY)
13 DESIGN / MAX. OPERATING PRESSURE
14 MAX DESIGN / OPERATING TEMPERATURE
15 MIN DESIGN / OPERATING TEMPERATURE
16 BODY MATERIAL DESIGNATION
17 SERVICE TEMP. Max ................. Min ...............
18 PRESSURE CLASS
19 MAX. DIFF. OPERATING PRESS ........................
20 BI-DIREC110NAL SHUTOFF YES 0 N/AO
21 MAX. OPERATING TORQUE (at max. differential pressure)
22 MAX. ALLOWABLE TORQUE - LIMITED BY STEM:
23 ALLOWABLE LEAKAGE RATE (Metal Seated Valves Only)
24
TYPE: DBB VALVE OR DIB VALVE YES 0 N/AO
CONSTRUCTION REQUIREMENTS:
BS EN ISOl7292 0 API6D /150 14313
0
M5SSP-ll0
0
25
MSSSP-72 0 ASME B16.34
0
FIRE5AFE DESIGN: API607 0 API6FA
0
15010497
0
26
FIRESAFE TYPE TESTED & CERTIFIED: 0
27 NOMINAL SIZE:
i 28 FACE TO FACE DIMENSION:
I 29 END CONNECTIONS:
i
30
CONSTRUCTION TYPE:
0 0 0 1-Piece 2-Piece 3-Piece
31 ENTRY TYPE: Side entry
n
Top entry
n
32 BALL TYPE: (Solid / Sealed Cavity / Cored Cavity / Hollow)
33 BALL SUPPORT: FLOATING 0 TRUNNION
0
34 ANTI STATIC: YES [] N/A
n
3S
CAVITY RELIEF METHOD:
36
BORE TYPE: FULL BORE
0
REDUCED BORE
0
37 OPERATOR: WRENCH GEAR ACTUATOR
~
/'
:I
DOC. NO. KOC-MP-033 PART 1 Page 30 of 37 REV. 1
38 ! PORT POSITION INDICATOR METHOD:
39
LOCKING DEVICE: YES
0
N/A
0
METHOD:
40 ANTI BLOWOUT STEM:
41 EXTENDED BONNET YES [] N/A
0
42
SEALANT INJECTION: YES 0 N/A 0
MANUFACTURER'S RECOMMENDATION:
43 OTHER BODYTAPPINGS
44 FOUNDRY QUALIFICATION: YES U N/A U
MATERIAL REQUIREMENTS:
45 BODY CASTING OR FORGING SPEC/GRADE
46 NDE OF BODY CASTINGS
47 NDE OF RING GROOVES: I
48 PMI ON CORROSION RESISTANT ALLOYS:
I
49 PURCHASER APPROVAL OF MAJOR CASTING REPAIRS: YES NO
50 STATE IF FLANGES OR BODY TO BE WELDED:
i
51 CARBON/C.E. LIMITATION:
52 BALL MATERIAl.:
I
53 ACCEPTABILITY OF PLATED BALL YES NO
54 SEAT MATERIAL:
0
5S
HARD FACING: - .. _. -. METAlSEATS
_.
0 BAll
--, ..
0
..-.-..
56 RENEWABLE SEAT RINGS YES NO
57 STEM MATERIAL:
58 TRU NNION BEARING MATERIAL AND PLATING IF ANY:
59 STEM SEAL
60 BODY SEAL GASKET
0 i
TEST REQUIREMENTS:
I 61
I TESTS REQUIRED AS PERTHIS STANDARD:
I I
MARKING, COATING, PROTECTION & PACKING REQUIREMENTS:
62 COlOUR CODE
63 ITEM CODE(S)
:
,
64 EXTERNAL COATING/PROTECTION
65 INTERNAL COATI NG/PROTECTION
66 END PROTECTION
67 PACKING
.68
NAME PLATE FIXING
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For Guidance Oni -Indicative Ins ecHon & Test Plan for Ball Valves Inspection and Test Plan
Suggested/Indicative Inspection & Test Plan for Ball Valves Project No/ Contract No
Applicable KOC Specification: I<OC-MP033 Part-1 Purchase order No:
Sr. No. I Component or Process' Characterestics to be I Type of Check I Extent I Reference document/ I Format of TYPE OF INSPECTION
checked of Acceptance Standard Record
2
3
Document Review
and approval
Vendor Pre.lnspection
Meeting
Castings I Forgings:
Casting/ forging
:n !qualification
( Body, Ball, Trunion,
,<;:ICover,Stem & Etc ... )
Review of PO I Data
sheets / drawings,l
Inspection & Test
procedures nnd welding
procdures.
Soundness of casting /
Forging
Chemical composition &
Mechanical properities
Heat treatment (HT)
Documellt
review,
First Pouring i
Forging witness
Review of
material test
reports.
Review of
heattreatment
chart
Check
100% KOC.MP-33.Pt.li &
Contract
requirements.!
!
As per the Contrllc\
document '
Refer lAS per KOC stand,\rd
Note-2 KOC-MP-33 Pt.l.
One per IAPPlicable Material
heat Specification '
Each
HT

Applicable Materia,l
Specific,Hio!1
Radiography Testil1g Volumetric As per As per Cumpany
Document /
ProcedlJrt'
Minutes of
Meeting
Qualification
Report
Valve Test
Certificate
HT chart
Valve
Mimufacture
H
H
H
H
I
I
I
1
1
J
I Ii
i (RT) for clItings & defects KOC- Approved RT /
"A! t:ltTasonic Testing (L:T) MP.:n procedure I!
i for Forgings '1 i
RT i VT
report
H
Contractor /
its
nominated
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R
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I Penetrant Testing,' Surface defects As per A.s per Company PT / 111T I I .
R
"; 'I ;'vl;Jgnehc Particle Testing KOC- Approved I'T / Report I H ;
I as '))11'\:(',)\11<:, pro<:edtlre. I
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Sr.:-.Io. Component or Process Characterestics to be Type of Check Extent Reference document I Format of TYPE OF INSPECTION
A
checked of Acceptance Standard Record
0
Check
Contractor II .
(')
I
Valve
3:
Manufacture
its KOC/its
"0
nominated nominated

TPI TPI
Q
W
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Visual Inspection Visual As per As per KOC standard Visual Hfor sub
"0
1.6
KOC- KOCMP33 Pt.1. fnspection Vendor & )0
MP33 Record Valve
R R

manufacturer
Dimensional Inspection Measurement Asper As per KOC standard Dimension H-for sub-


KOC- KOC-Mp33, Record Vendor & r--
.1
MP-33 Valve
R R
manufacturer
Positive material Verification of Applicable Material )?MJReport
Identifica tion on chemical Specification and
"0
:<.8 100% H }vlin 20% W Min 10% \'\'
I)
Corrossion resistant composition Company approved
(,Q
alloys or overlays, procdure,
CD
W
Hardness Test ( for Material test Applicable Material Valve Test
N
valves under Sour report I Lab Specification and Certificate
0
....
1",1 Sourvice) report.
40%
NACE MR 0175/150
H Min 20% W ,\lin H)'Yo IV W
1
15156 & Company
.....
approved procedure.
Fasteners uSllld [!ilr
.J
I2ressure retainng
-
comRonents:
Chemical composition &: Material test One per Applicable Material Material Test
..j .1
Mechanical properities
report, Heat Specification Certificate
H R R
Hardness Test Material test
As per
Applicable Material Material Test
! report / Lab Specification and Certificate,
+:21
report.
Material
NACE MR 0175 IISO
H :Vlin 20'1., I,V Min HiW. W
spec
15156. :;0
5
Final Insl1li:ctioD

Visual & Dimensional Visual&: As Per KOC standard Valve test

,
Examination after final KOCMP.33&
-; Ii
Dimensional
100%
certificate
H 'vlin \ \' \thn 'IV
0
. i
assemblv Check.
Approved vC\lve
drawings
I

I
c
0
p
Z
Sr. N0'1 Component or Process
Characterestks to be Type of Check Extent Reference documentl Format of TYPE OF INSPECTION P
checked of Acceptance Standard; Record A
Check
I
0
I
I
Contractor II
(")
Valve I
Manufacture
its KOCI its
i:
nominated
"0
r
TPI TPI
Q
Shell Hydrostatic testing Check for As Per KOC standard ! Valve test
W
W
5""f
visible leakage
100%
KOC-MP-33 Pt. 1 & certificate
H Min2ll%W Min IN
"0

Company approved I
procedure.
"
Valve Closure test Check for As Per KOC standard I Valve test

visible leakage certifica te
.....
3.3 100%
KOCMP33 Pt.1 & I
H Min :!O% W !I.'iiI110% W
Company approved
,
procedure.
Electical Continuity Anti-static As Per KOC standard i Test Report
:; .1\
between body, ball and design Type KOCMP33 Pt 1 & ;
H W/R
stem test Company approved
i
"0
procedure.
i
IU
CO
Surface preparation and Visual As per KOC standard I Painting CO
5.5 Painting on the valve examination &
100%
KOCPOOl & Company Report Ii :-.lil1 20% IV :-li1\ ](1'\ \" W
OFT check approved procedure, :
W
0
Documentation
i
....
6
I
w
!
.....
Final Inspection Release Issue of release As Per KOC standard I Release note
Ii,l
note note
100% KOCMP33 Pt.1 i
H H H
!
I
. Release note Release for As per Contract i Shipping
, ,
. despatch
100% requirements. i Release H H R 0'._
! nnte
Manufacturing Record Review of As per Company : MRB
6.,:\
Book Documents
100%
approved MRS index i
H H H
Note: (1) This suggested/Indicated Inspection &. Test Plan(ITP) is for guidance only. The shall prepare the ITP based on
manufacturing plan, Contractual requirements, as per the guidelines of this indicative ITP:and submit for Company approval.
"
(2) At the start of production for each size and class.
m
i ITPNO. :
:<
. REV.NO. :
.....
DATE :
(PREPARED BY) (CHECKED & APPROVED BY)
,...J.


c
o
(')
l>
" Z
RECOMMENDED MATERIAL FOR BALL VALVE COMeONENTS ACCORDING TO FLUID/SERviCe 0
z "
Sr.No. Fluid Handled Body,Bonnet Stem,Trunnlon Ball Spring Body Studs,Nuts
A1,93 B71A194,2H <: s:
1 PI t A' 0' I 'I L GI I CS: A105 or A216 3165S t .1) RPTFE inconel X- With Electro-Zinc "p
an Ir, lese 01. ean yco WCB '" 0 e 750 Plating as per 0
ASTM B633
Bronze 661(UNS "
Bronze B61(UNS C92200) upto l>
C92200) upto NPS 1 Y. Ni.AI Bronze 8148 NPS 1 Y. 8. Ni-AI Inconel X-
2 Potable Water & NIAI Bronze 8148 UNS C95800 Bronze B148 I! RPTFE 750 Copper Alloy ..
UNS C95800 above UN5 C95800 i!
NPS 1Y. above NPS 1% :
I I Bronze B61 (UNS Bronze B61 (UNS :
; C92200) upto NP5 2 & C92200) upto i
! < NiAI Bronze 8148 Ni-AI Bronze B148 NPS 2 & NI-AI i RPTFE Inconel X C All
i-I UNS C95800 above UNS C95800 Bronze B148 ' 750 opper oy CC
i NP52 In internally UNS C95800 i , CD
H
I Brackish Water (With no coated CS piping above NPS 2 ; I
I H25}.Fire Water Bronze 861(UNS Bronze 861(UN5 : a
C92200) upto NPS 1 Y. C92200) upto
) 4 & NI-AI Bronze B148 Ni-AI Bronze B148 NPS 1 Y. & NiAI i RPTFE Inconel X C All
I I
UNS C95800 above UNS C95800 Bronze B148 750 opper oy
NPS 1 Y. in RTRP UNS C95S00
i piping above NPS 1 %
i Chemical Injection, Instrument : In I X- A19388MIA194
! 5 Air,Rich Glycol,any other non 31655 31655 31655, RPTFE 8M
, sour service with 55 piping
Hydrocarbon Oil,Gas &
Condensate with Chloride ,A193 B7MfA194
6 content less than or 50 CSA105 or A216- 3165S 316S5(Note.1)' RPTFE Inconel X 2HM Electro-
pp:n (sour service) for minimum WCB 750 Zinc Plating as per ;;0
design temperature upto minus ASTM 8633 IT!
29C 'I
I
c
0
0
.
z
p
Sr.No. Fluid Handled Body,Bonnet Stem,Trunnion Ball
!
Seat Spring ! Body Studs,Nuts
"
0
i
0
Hydrocarbon Oil,Gas &
,
I
==
Condensate with Chloride A320 L7M with
"tJ
7
content less than or equal to 50 L TCSA350 LF2/A352
316SS 316SS(Note-1) RPTFE
Inconel X- Electro-Zinc I
ppm (sour service) for minimum LCB 750 Plating as per
0
! W
design temperature below minus ASTM B633 w
29C and upto minus 46C "tJ

i
:;;0
Hydrocarbon Oil, Gas & I
-I
Condensate with Chloride
!
A193 B7M/A194
6 Mo Austenitic

8
content greater than 50 ppm CSA105 or A216- 6 Mo Austenitic SS
SS(UNS! RPTFE
Inconel X- 2HM with Electro
(sour service) for minimum WCB (UNS NOB926) 750 Zinz Plating as per
design temperature upto minus
NOB926) r
ASTM 8633
29C
Hydrocarbon Oil, Gas &
!
"tJ
I
i
II)
Condensate with Chloride A320 L7M with CC
content greatertban 50 ppm L TCS-A350 LF2/A352 6 Mo Austenitic SS
6 Mo Austeni\ic
Inconel X ElectroZinc
ft)
9
(sour service) for minimum LCB (UNS NOB926)
SS (UNS : RPTFE
750 Plating as per
W
NOB926) . en
design temperature below minus ASTM B633
0
29C and upto minus 46C
i
W
Hydrocarbon Oil,Gas, I
.....
I 10 Condensate, and Rich Glycol 316SS 316SS 316SS(Note-1) RPTFE
Inconel X A193 BBM/A194
PipiMlSour Serviclti
750 BM
Effluent Water, Oily Super Duplex Super Duplex
Super Duple/<
Stainless Steel Inconel X. A193 BBM/A194
11 Water,Produced Water,OftSpec Stainless Steel with Stainless Steel with
with PREN
RPTFE
750 BM
Oil (sour service) PREN exceeding 40 PREN exceeding 40
exceeding 40
Note-1-Solid 316 SS Ball for Valve sizes upto 12" and CS Bali+ENP coating for Valve sizes 14" and above
Note 2-For classes 900 and above, metal to metal seat shall be considered.
Materials used for valves in sour service shall conform to the requirements of NACE MR0175 i ISO 15156
:::0
m



(
DOC. NO. KOC-MP-033 PART 1 Page 36 of 37 REV. 1
ACKNOWLEDGEMENT
This KOC Standard has been approved by the Standards Technical Committee (STC)
consisting of the following:
Mr. AlRedha AI-Haddad
Mr. Mohammad Emam
Mr. S. Kumar
Mr. A. Unnikrishnan
Mr. Khalaf Hamada
Mr. N. Ramanathan
Mr. Abdul R. AI-Shammari
Mr. Ali Hassan AI-Failakawi
Mr. Daniel Pino
Mr. Haithem Aboghait
Mr. Gopal Murti
Mr. Abdul Aziz Akbar
Mr. Richard Arthur
Standards Team
Insp. & Corr. Team (S&E)
Standards Team
Standards Team
Design Team
Export Facilities Team
Insp. & Corr. Team (N&WK)
HS & E Systems Team
Utilities Team
General Projects Team
Opns Tech Svcs Team (WK)
Project Mgmt. Team (NK)
Info Systems Planning Team
Chairman
Dy/Chairman
Secretaryl Member
Member
Member
Member
Member
Member
Member
Member
Member
Member
Member
The draft of this KOC Standard had been-circulated to-the KOC User Teams for review and
the responses were received from the following:
TECHNICAL SVCS DIRECTORATE
Team Leader HSE (TS)
SOUTH & EAST KUWAIT DIRECTORATE
Team Leader HSE (S&EK)
EXPORT & MARINE OPNS. GROUP
Team Leader Export Maintenance
Team Leader HSE
MAJOR PROJECTS GROUP
Team Leader Project Support
AHMADI SERVICES GROUP
Team Leader Utilities
Team Leader Proj. Design
OPERATIONS GROUP (SK)
Team Leader Opns. Tech. Svcs
SUPPORT SVCS GROUP (S&EK)
Team Leader General Projects
NORTH KUWArr DIRECTORATE
Team Leader HSE (NK)
WEST KUWAIT DIRECTORATE
Team Leader HSE (WK)
ENGINEERING GROUP
Team Leader Design
Team Leader Construction
HSEGROUP
Team Leader HS& E Systems
Team Leader H& E
Team Leader Safety
GAS MANAGEMENT GROUP
Team Leader Consumers Networks
Team Leader Gas Operations
SECURITY & FIRE GROUP
Team Leader Fire
~
~ - - - - - - - - - - - - - - - - - - ~ - - - - - - - - - - - - ~ - - - - - - - - - - - - - - - - ~ r
DOC. NO. KOC-MP-033 PART 1 Page 37 of 37 REV. 1
This KOC Standard for Valves: Part 1- Ball Valves (KOC-MP-033) has been
prepared by the Task Force (TF-MPI14) comprising ofthe following members:
Mr. Mohsin Mirza
Mr. H. Reddy
Mr. K. Subramanian
Mr. Ashish Kumar
Standards Team
1& C Team (N&W)
I & C Team (S&E)
Design Team
TF leader & Author
Member
Member
Member
Ex: 61371
Ex: 61479
Ex: 61574
Ex: 61768
D