PROCEDURE FOR PROCESS VALVE RECONDITIONING

Following procedure shall be followed for reconditioning of process

valve

PART-I: INITIAL INSPECTION

1.0 INTRODUCTION

Scope of work includes reconditioning of the gate, globe, plug, check, ball,
butterfly valve upto 46" dia and 150, 300, 600, 900 & 1500 rating valves at
vendors workshop including to/fro transportation and octroi formalities.

Following is the BPCL standard procedure for reconditioning of the

valves which shall be followed during reconditioning of valves.

2.0 SCOPE

This procedure describe the methods/steps for reconditioning the Gate

valves, Globe valves, Plug valves, ball , butterfly valves & Check valves of
different materials such as carbon steel, low alloy steel and stainless steel.

3.0 LIKELY LOCATIONS OF DETERIORATION

3.1 GASKET FACES

The most critical location of a valve is its gasket contact face. Flanges suffer
damage on serrations. Also in few cases, gasket faces have been found to
have severe erosion in the form of groove forming.
Serrations of the raised face also get mechanically damaged by improper
handling. Such flange joints are prone to leak.

3.2 BOLT HOLES

Bolt holes get damaged by forced insertion of tommy bars to align

improperly fitted flange joint. They may get damaged also due to corrosion
(crevice and / or galvanic).

3.3 INTERNAL DETERIORATION

Valve body and back seat may get attacked internally by either corrosion or
erosion or both.

3.4 STEM

A stem along with its hammer joints get attacked by either erosion or
corrosion or both. The stem is also subjected to wear due to hardened
packing. It may get bent or damage due to improper handling.

3.5 SEAT RING & DISC/WEDGES

Seat rings may get attacked by crevice corrosion. It may also be subjected
to erosion due to uneven seating of disc on seat ring.

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 4.0 INITIAL VISUAL INSPECTION OF VALVE

The valve parts shall be thoroughly cleaned both internally & externally free
of rust, dirt etc. by wire brushing, using rust removal or any other means.

After the above, the valve shall be offered for inspection.

Original identification marks / stamping on body and bonnet giving details
of size, rating and material etc. should be legibly clean.

The marks/stamping shall be encircled by paint prior to offering for

inspection.

PART- II : RECONDITIONING PROCEDURE

5.0 INSPECTION OF PARTS

After a valve is found acceptable in initial visual inspection, the same shall
be dismantled and all its parts offered for detailed inspection.

The valve shall be categorized as follows in two categories during inspection.

1. Valve for reconditioning: These shall be repaired as per the procedure

given in this standard and after repair shall be used in service.

2. Valves declared scrap which is beyond economical repair and for reasons
given in Part II.

5.1 BODY & BONNET

Valves having notches, grooves on body and bonnet shall be removed by

chipping / grinding and offered for DP Test. After successful DP Test, the
same shall be filled up with welding using suitable electrodes as
recommended in Annexure-I.

5.2 GASKET FACES

Any damage to the gasket faces shall be removed by grinding and built up
by welding and re-machined to its original shape. Refer Section 9.0 of this
procedure.

5.3 STEM

Corroded / eroded and bent / damaged stem shall be replaced with a new
one with original standard dimensions. No repair shall be permitted on the
stem. Dimension selected for stem diameter / length and hammer joint
shall be as per the Original Valve. If any valve requires replacement of the
stem same shall be carried out after obtaining approval from client.

5.4 SEAT RINGS

Seat rings shall be replaced if found corroded / eroded. The original

fastening method to body shall be employed during replacement. Further
they shall have the hardness in accordance with API 600 Trim.
Reconditioning of renewable type seat rings is not allowed.

5.5 DISC / WEDGES

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 i) Damaged disc / wedge seating surface shall be built up by welding,
machined and carefully refitted to match the seat ring.

ii) The centre of the wedge shall not drop below the centre line of the
valve.

Differential hardness of 50 HB between seat and disc, as per BPCL

Specifications shall be maintained.

No welding is allowed on the disc for building up parent metal. They shall be
replaced with new one.

5.6 HAMMER JOINT

Any damage to the hammer joint between stem and wedge shall call for
rejection / replacement.

5.7 GASKET AND PACKING

All gaskets and packing shall be replaced to suit the temperature and
pressure rating as per relevant API specifications. Old gaskets / packing
shall not be reused.

5.8 BOLTING MATERIAL

All damaged bolting material shall be replaced with new ones with relevant
specifications.

6.0 HEAT TREATMENT

The valves required to be repaired by welding shall be preheated and post

weld heat treated as per Annexure I & II depending upon the metallurgy.
Refer para 9.0 for additional details.

7.0 FINAL TESTING

Each valve after reconditioning shall be subjected to hydrostatic, seat,

backseat and pneumatic tests as per related API Standards / BS standard
Specifications.

8.0 IDENTIFICATION / CERTIFICATION

i. Each valve after reconditioning shall be prominently hard punched on the

flange, showing the date of reconditioning and the test pressure.

ii. Proper testing certificates as necessary shall be provided along with each
batch of valves.

9.0 REPAIRS BY WELDING / MACHINING

i) Defects shall be completely removed by chipping or grinding to sound metal

and shall be checked by Dye Penetrant Test.

ii) Deposit the weld metal using electrodes specified in Annexure I suitable for
the respective material. Except body / bonnet flange faces, mechanical

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 marks / defects not deeper than 1 mm shall be acceptable and no
deposition of weld is required. For WCB Casting, wherever the depth of any
cavity prepared for welding exceeds 20% of the wall thickness or 1 inch
( whichever is smaller), or the total area covered by welding is greater than
10 sq. inch shall be radiographed & also Stress Relieved (SR). For Alloy
Steel Valves, Stress Relieving is mandatory.

iii) Wherever required excess weld deposition shall be carried out to facilitate
machining to original contour.

iv) The weld surface and nearby area shall be free from defects on checking
with Dye Penetrant Test.

v) Unless otherwise specified, concentric serrations shall be provided on gasket

faces.

vi) Dimensional details shall confirm to the respective API/BPCL specifications.

vii) Welding shall be carried out with appropriate approved welding procedure
and using qualified welders only.

10.0 INSPECTION STAGES

The valves shall be offered for inspection at the following stages:

a. The valve in dismantled condition with all its parts accessible for inspection
prior to reconditioning.

b. After chipping / grinding the defective / deteriorated area to sound metal

for DP Test.

c. After final machining for DP Test.

d. After complete assembly for visual inspection / operability.

e. Various pressure tests as per applicable API / BS standards.

f. Visual inspection prior to sending to Warehouse or Site.

11.0 DISPATCH

i. After inspection the valves shall be dried, cleaned and painted with two
coats of Zinc Phosphate Primer followed by 2 coats of Aluminium paint.

ii. PVC caps / suitable protection shall be provided on both ends of the valves
prior to dispatch.

12.0 MATERIAL ACCEPTANCE

i) Each valve after re-conditioning / testing as stipulated above shall be

stamped by Inspector and released for dispatch.

IMPORTANT

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 Any valve without original identification marks / stamping for body material
and valve rating shall not be used for reconditioning.

Depending upon the condition of the valve / valve parts recommendation

for repairs shall be given.

THE VALVES SHALL CALL FOR OUTRIGHT REJECTION IF:

i) Original identification marks / stamping with regard to body material

and valve rating is not available / visible.
ii) The valve is excessively corroded / damaged internally / externally.
iii) The weld repairs may cover more than 20% of the valve surface area.
iv) Valve has been originally FRE lined for salt water application.
v) Valve suffered body corrosion / erosion beyond 3 mm.
vi) Valve having body cracks / leakages

Note:

i. Transportation of the valve from BPCL Mahul refinery to your workshop and
delivering back to refinery is in contractors scope. For valve movement out
side Mumbai limit, contractor shall complete all octroi formalities including
payment of deposits etc.

ii. All stage wise and final inspection shall be carried out.

iii. After award of contract, contractor shall prepare Quality Approval Plan
applicable to CS / AS valve and get the same approved from Owner. This
QAP shall be applicable till the completion of the entire job under said
contract.

iv. For butterfly valve carry out replacement of seal ring and damaged
fasteners of clamp ring. Balance scope remains as described for other
valves.

v. For plug valve supply of Audco grease is in your scope.

ANNEXURE - I

DETAILS OF WELDING ELECTRODES & HEAT TREATMENT REQUIREMENT

MATERIAL WELDING ELECTRODES PREHEAT/INTERPASS

TEMPERATURE (DEG. C.)

A-216 WCB E-7018 80-120

A-217 WC6 E-8018-B2 150-200
A-217 WC9 E-9018-B3 150-315
A-217 C5 E-502-15 / 16 200-250
A-217 C9 E-505-15 / 16 200-250
A-351 CF8 E-308-15 / 16
A-351 CFSM E-316-15 / 16

ANNEXURE - II

DETAILS OF POST WELD HEAT TREATMENT

A. MATERIAL QUENCHING MEDIA : A-216 WCB

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RATE OF HEATING DEG :Not to exceed 200 deg. Per Hr.

SOAKING TEMP. DEG C: 600-640

SOAKING TIME : 1Hr. per inch thickness

COOLING RATE : Not to exceed 200 deg. C. per Hr.

B. MATERIAL QUENCHING MEDIA : A-217 WC6 /WC9

RATE OF HEATING DEG :Not to exceed 200 deg. Per Hr.

SOAKING TEMP. DEG C: 595 minimum.

SOAKING TIME : 1Hr. per inch thickness

COOLING RATE : Not to exceed 200 deg. C. per Hr.

C. MATERIAL QUENCHING MEDIA : A-217-C5 / C9

RATE OF HEATING DEG :Not to exceed 200 deg. Per Hr.

SOAKING TEMP. DEG C : 675 minimum.

SOAKING TIME : 1Hr. per inch thickness

COOLING RATE : Not to exceed 200 deg. C. per Hr.

D. MATERIAL QUENCHING MEDIA : A-315 CF 8 / CF8M

RATE OF HEATING DEG :Not to exceed 200 deg. Per Hr.

SOAKING TEMP. DEG C : 1040 minimum.

SOAKING TIME : 1Hr. per inch thickness

COOLING RATE : Quenching Water

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