KOC-I-010

/'-\

*

o&

(g.l..j) ca¡¡íJt J¿¿¡ t5,pKUWAIT OIL COM PANY (KS.C.)

STANDARDS PUzuGAT¡ON

KOC STANDARD

FOR

GONTROL AND SHUTDOWN VALVES

DOC. NO.'KOG-I-010

STANDARDS TEAM

ffi,

KOC-I-010DOC. Pase 1 of 35 REt/.1

rd,

*d.o

KOC STANDARD

FOR

CONTROL AND SHUTDOWN VALVES

DOC. NO. KOC-|-O10

ISSUING AUTHORITY:

STANDARDS TEAM

1 31.03.2002 /ss¿cdas KOC Standad

Rêv. Date Desc¡iptlon

Task Fo¡c¿

sil. Enü. Stds.

Ct

of 35DOC. NO. KOC-|-O1o REV.l

r/t

TABLE OF CONTENTq

FOREWORD

1.O SCOPE

PAGE NO.

5

6

6

'666

777

9

I

2.O

3.O

APPLICATION

TERMINOLOGY3.1 Definitions3.2 Abbreviations

4.O REFERENCE CODES & STANDARDS4.1 Gonflicts4.2 List of Standards and Codes

5.O ENVIRONMENTAL CONDITIONS

6.0 HEALTH, SAFETY AND ENVIRONMENT

7.O SERVICE CONDITIONS7.1 Gorrosive $ervices7.2 Suitability for Specific Service

I9f0

8.O CONTROL VALVES8.1 General requirementsA.2 Valve Body8.3 Valve Trim8.4 Bonnet8.5 Packing Box Assembly and Packing Materials8.6 Seat Leakage

10101112131314

9.O CONTROL VALVE ACTUATORS9.1 General9.2 DiaphragmActuators9.3 Piston Actuators9.4 HydraulicActuators9.5 Self Actuated Control Valves9.6 Etectrlc Actuators

14141516161617

10.0 CONTROL VALVE ACCESSORIES10.1 Valve Positioners1O.2 Air Lockup Kits1O.3 Transducers1O.4 Handwheels1O.5 L¡m¡t Sw¡tches10.6 Air Filter Regulator Sets1O,7 Solenoid Valves10.8 Air Volume Booster Relays

171719191920?Ð2b21I10.9 Mounting of

DOC. NO. KOC-|-O1o of 35 REV.1

rf'

*

o

11.O

12.O

14.O

VALVE NOISE, FLASHING AND CAVITATION11.1 Valve Noise11.2 Flashing and Cavitation

SFIUTDOWN VALVES12.1 General12.2 Seat Leakage12.3 Actuator for Shutdown Valves12.4 Air Reservoirs12.5 L¡m¡t Switches12.6 Solenoid Valves12.7 PushbuttonControl12.A Vaþe Position lndicators

212122

222223232424242525

25

26262627

272727282A28

29

292930

30

30

313131313232

13.0 F¡RE PROTECTION

IDENTIF¡CATION NAMEPLATES14.1 ldentification of Control and Shutdown Vatves14.2 ldentification of Valve Accessories14.3 lndication of Direction of Flow

PERFORMANCE, INSPECTION AND TESTING REOUIREMENTS15.1 General15.2 lnspection and Testing Plan15.3 Valve Testing15.4 Actuator Testing15.5 Gertification

15.O

16.O ELECTROMAGNETIC COMPATIBILITY AND RADIOFREOUENCY INTERFERENCE (RFI}

17.O EOUIPMENT IN HAZARDOUS AREA17.1 General17.2 Hazardous Area Certification

18.O

19.0

20.0

OUAL¡TY ASSURANCE

PACKING. MARK¡NG AND DOCUMENTATION

SPARE PARTS AND MAINTENANCE REOUIREMENTS2Oj General2O.2 ConstructionSpares2O.3 GommissioningSpares2O.4 Operating Spares2O.5 lnsurance Spares

21.O APPENDIX.I DATA SHEET FOR CONTROL VALVE

APPENDIX-2 DATA SHEET FOR SHUTDOWN VALVE

ACKNOWLEDGEMENT

33

34

35


"1"

b)

c)

FOREWORD

This document "KOC Standard for Conüol and Shutdown Valves" (KOC-|-O10) is

intended to provide minimum requirements for Control Valves and ShutdownValves to be installed at KOC Facilities in Kuwait.

This Standard has been approved by the Standards Team in consultation with theStandard Technical Committee {STC} for use throughout the corpirrate Engineeringand operational functions of Kuwait Oil Company (K.S.C.).

This Standard sets out to achieve the following objectives:

a) to provide technical guidance and establish the base document fordeveloping proþct/material specifications for control and shutdown valveswith a view to achieve uniformity, quality, reliability and efficiency in an

economical manner.

to maintain the KOC requirements of safety and protection to plant,personnel and environment established by KOC's Fire & SafetyRegulation, Health, Safety & Environmental Management System(HSEMS) and HSE Policy;

to set out minimum features required, Data Sheets have been includedwhich will act as a checklist to ensure that all requirements for design,construction, inspection and testing of control and shutdown valves are

covered.

Feed back as well as any comments or suggestions derived from the application ofthis Standard at any stage of design, construct¡on or operation are invited andshould be directed to:

Team Leader Standards Team(Chairman, Standards Technical Committee)Loss Prevention Group, K.O.CP.O.Box-9758, Ahmadi- 61 OO8State of Kuwait.

Task Force responsible for this Stqndard

The preparation of this Standard was entrusted by Standards Technical Committeeto the Task Force (TF-|/O2) comprising of the following members:

Dr. Mohammad llyasMr. A.UnnikrishnanMr. Louis ThiagarajMr. G.Santhosh KumarMr. S.Chandrasekhar

(Standards Team) : Task Force Leader(StandardsTeam ) : Author/ Member(Maint.Team East) : Member(lnspectionTeam) : Member(Opns.Tech.Svcs.Team-S) : Member

Tel No.61406Tel No.61633Tel No.22416Tel Nb.61250Tel No,22122

(,

DOC. NO. KOC-|-Olo of 35 REV.l

r/'

*

o

Ct

1.0

1.1

1.2

2.O

2.1

2.2

2.3

3.O

3.1

3.1.1

SCOPE

This Standard spec¡f¡es the minimum requirements for Control and

Shutdown Valves, including actuators and accessories for installation at

various facilities within KOC.

This Standard also covers the performancei .inspection and testingrequirements for Control and Shutdown Valves.

APPLICATION

The design, material of construction, performance, inspection and testing ofControl and Shutdown Valves shall comply with all the relevant requirements

specified in this Standard and the reference standards / codes ment¡oned

herein. Proþct specific requirements, shall be indicated in the Data Sheet.

Any exceptions or deviations from this Standard, along with their merits and

justifications, shall be brought to the attention of KOC's Controlling Team fortheir review, consideration and amendment by Standards Team (if required).

Compliance with this KOC Standard does not of itself confer immunity fromlegal or statutory obligations

TERMINOLOGY

Definitions

For the purposes of this Standard, the foltowing definitions apply.

Fouling

The build up of process fluid or debris on the trim parts of the valve.

3.1.2 Sulphide Stress Cracking

Brittle failure by cracking under the combined action of tensile stress and

corrosion in the presence of water and HrS.

3.2 Abbreviations

EIP

EMC

EMI

ESD

Voltage to Pneumatic

Electromagnetic CompatibilitY

Electromagnetic lnterference

Emergency Shutdown

DOC. NO. KOC-|-o10 of 35 REV.l

N

**rt*r;.{t/

r/"

*úo

4.O

FCI Fluid Controls lnstitute

F&G Fire and Gas

HIC - Hydrogen lnduced Cracking

H-S Hydrogen Sulphide2

HSE Health, Safety and Environrnent

HSEMS Health, Safety & Environmental Management System

ISA The tnstrumentation, Systems, and Automation Society

KOC Kuwait Oil Company (K.S.C.)

MSS - Manufacturer's Standardisation Society of the Valveand Fittings lndustry lnc.

NPS - Nominal Pipe Size

PFD - Process Flow Diagram

P&lD Piping and lnstrumentation Diagram

PTFE - Polytetrafluoroethylene

RFI Radio Frequency lnterference

REFERENCE coDEq AND STANDA\RDS

Conflicts

ln the event of conflicts between this Standard and the tatest edition ofstandards/ codes referred herein, or other purchase or contractualrequirements, the most str¡ngent requirement shall app¡y.

List of Standards and Codes

Control and Shutdown Valves shalt conform in design, manufacture,performance and testing, except where otherwise specified, with thecurrent issue of the applicable codes and standards. of which thefollowing are listed : ...'.

lnternational Standards i'l

4.1

4.2

Degrees of Protection Provid

4.2.1

rEc 60529

oe

osures


ar*

iì

2

*

od.

IEC 60534 Parts 1-8 lndustrial Process ControlValves

lEc 61000 Electromagnet¡c Compatibility (EMC)

4.2.2 National Standards

API 6FA

APt 553

APr 607

ASME SEC VIII DIV 1

ASME 816.5

ASME 816.34

ASTM 4193

ASTM A32O

FCt 70-2

¡sA 75.01

tsA 75.03

lsA 75.04

MSS-SP 25

NACE MR 0175

4.2.3 KOC Standards

KOC-E.004Part-1

Specification for Fire Test for Valves

Refinery ControlValve

Fire Test for Soft -Seated Ouarter-Turn Valves

Rules for Construction of Pressure Vessels

Pipe Flanges and Flanged Fittings NPS 1/2 throughNPS 24

Valves - Flanged, Threaded and Welding End

Standard Specification for Alloy-SteelStainless Steel Bolting Matérials forTemperature Service

andHigh

Standard Specification for Alloy/Steel BoltingMaterials for Low Temperature Service

Control Valve Seat Leakage

Flow Equations for Sizing Control Valves

Face-to-Face Dimensions for lntegral FlangedGlobe Style Conûol Valve Bodies

Face-to-Fâce Dimensions for Flangeless ConûolValves

Standard Marking Systems for Valves, Fittings,Flanges and Unions

Sulfide Stress Cracking Resistant MetallicMaterial for Oilfield Equipment

KOC Recommended Practice for Selection,Installation and Maintenance of Electrical

,' 'Equipment in Hazardous Areas: GeneralRequirements


,r/t

KOC-E-OO4 Part-2

KOC-E-OO4 Part-3

KOC-G-OO2

KOC-G-004

KOC-G-OO7

Flameproof Enclosure "d"

lntrinsic Safety "i"

KOC Standard for Hazardous Area Ctassification

KOC Standard for Packing, Marking and

Documentation

KOC Standard for Basic Design Data

KOC-G-OOg KOC Standard for Spare Parts and MaintenanceData

KOC-P-oo1 KOC Standard for Painting and Coating of MetalSurface-New Construction

5.0 ENVIRONMENTAL COND¡TIONS

5.1 The environmental conditions in Kuwait are severe and shall be

considered carefully before selection of Control and Shutdown Valves. All

the equipment shall be suitable for continuous operation at a deserttocation under high ambient temperature and humidity. The atmosphereshall be considered to be dusty and corrosive and may contain traces ofhydrogen sulphide.

5.2 Refer to "KOC Standard for Basic Design Data" (KOC-G-OO7) whichprovides the detailed design information regarding the environrnental, siteand utility supply conditions prevailing throughout the KOC Facilities.

6.0 HEALTH. SAFETY ANp ENVIRgNI\'IENT

All relevant safety requirements of KOC's Fire & Safety Regulation,Health, Safety & Environmental Management System (HSEMS) and HSE

Policies shall be adhered to while performing the Control and ShutdownValve design and installation.

7.O SERVICE CONDITIONS

7.1 Corroqilre Services

7.1.1 General

Materials used for the manufacture of the Control and Shutdown Valvesshall be suitable for the application specified in the Data Sheeit' and be

electrochemically compatible with actuator, process piping and securingbolts and brackets.

.Ã

DOC. NO. KOC-|-Oî0 of 35 REV.1

r{'

*r¿o

7.1.2 Sulphide Stress Cracking Considerations:

a) The materials, manufacturing methods and testing for all Controland Shutdown Valves to be installed in hydrocarbon fluid serviceshall be in accordance with the requirements of NACE MROl75specification.

b) The requirements stated in clause 7.1.2{'a1 above shall apply to all

components of valves and valve accessories that can come intocontact with the process fluid and its vapour

7.1.3 Hydrogen lnduced Cracking Considerations:

Consideration shall also be given to the likelihood of hydrogen inducedcracking (HlC). Where resistance to HIC is specifically called for in thespecification/data sheet, the Control and Shutdown Valves and itscomponents shall be manufactured using materials not susceptible to HIC

and prior approval from KOC shall be taken on this regard.

7.2 Suitabiliûr..forSpecificService

The valves and all its accessor¡es to be installed 'in any other service, as

specified in the project specification/Data Sheet shall be suitable foroperation in such services without any adverse effect.

8.0 CONTROf- VALVES

8.1 General Reouirements

8.1.1

8.1.2

8.1.3

Control valves used for the control, throttling and regulating of processflow shall be selected to meet the pressure drop, temperature,performance and rangeability requirements.

Globe type control valves are normally used for all general applications,and characterized ball valves are used for control of large volume of flowor high shutoff requirements.

Double-seated full-ported ball valves are used for on-off application;eccentric rotating plug valves are used for large volume, low-pressuredrop applications; angle valves are used where it is necessary to preventthe accumulation of solids, and on erosive or flashing service.

8.1-4 The globe-bodied valves shall be "iop and bottom" guided or cage guidedunless otherwise specified in the Data Sheet.

i'.Valves shall be sized on the basis of technical parameters specifiád in the8.1 .5Data Sheets, P&lD, PFDcontrol and rangeabillty.

, equipment and piping data, rovide adequate

DOC. NO. KOC-!-010 Page 1O of 35 REV.l

"

r*

*

8.1.6 The rate of flow and pressure drops under design conditions, as well as otherknown factors such as fluid temperature, density, viscosity and vapourpressure shall be considered while sizing of valves . Valve sizing calculationsshall be performed based on ISA 75;01. Calculations submitted bymanufacturers based on any other equivalent standard shall be subject toKOC approval.

8.1.7 The sizing shall be such that the normal design flow is between 7Oo/o andgO% of the fully open valve capacity, unless otherwise specified.

8.1.8 Where three-way valves are specified, it shall be clearly identified as flow-mixing or flow-splitting in accordance with the intended application.

8.1.9 Three-way valves shal! be capable of operating against the maximumdesign differential pressure that can exist across a single port.

8.2 Valve Bodv

8.2.1 The pressure rating of control valves shall be to pipe line rating with a

minimum of ANSI class 300 for valves of 2OOmm (8") sizes and below.

8.2.2 Unless otherwise specified in the Data Sheet, the control valve shall beflanged type to facilitate removal of the vatve from the pipeline. Theflanges shall be in accordance with the requirements of ASME B 16.5.Butt welding/screwed ends shall be subject to KOC approval.

8.2.3 In case of butt-welded type, the valve body mater¡al shall be weldcompatible with the adjoining pipe material.

8.2.4 The Face-to-Face dimensions for integral flanged globe style controlvalves shall comply with the requirements of ISA 75.03. and Face-to-Facedimensions for flangeless control valves shall comply with therequirements of ISA 75.04. Face-to-Face dimensions based on any otherequivatent standard shall be subject to KOC approval.

8.2.5 Control Valve body material shall be selected based on the pressure andtemperature requirements and shall be resistant to corrosion, erosion andcavitation effects of the fluid to be handled.

8.2.6 The size of globe and ball valve body shall not be less than two pipe sizes

smaller than the line size.

8.2.7 The minimum size of globe and ball valve bodies shall be NPS 1. Bodysizes corresponding to NPS 1-114, NPS 2-112, NPS 3-',112, and odd'Sizesabove NPS 4 shall not be used. r'l

DOC. NO. KOG-|-o10 of 35 REV.l

,VL

8.3 Valve Trim

8.3.1 The valve trim consists of the removable internal parts of the valvecontacting the flowing fluid, which includes the valve seat, plug, stem,cage etc.

8.3.2 The trim shall be of top entry design to facilitate easy maintenance andreplacement.

8.3.3 The process design. shall specify the type of control valve trim appropriatefor the required flow characteristic viz. Quick Opening, Linear, Equal

Percentage and modified equal percentage as applicable.

8.3.4 The valve character¡stic shall be selected so as to obtain a linear installedvalve characteristic over the operating range.

8.3.5 Equal percentage plugs are generally used for flow control applicationsand linear plugs for applications where most of the system pressure dropoccurs across the control valve.

8.3.6 The flow direction shall be such that the flow tends to close the valve forliquid services unless otherwise specified.

8.3.7 The valve internals including bohing materials shall be selected for theindividual service, meeting the NACE 0175 as a minimum for all hydrocarbonservices.

8.3.8 The manufacturer shall provide the control valve trim suitable for the serviceconditions specified and ensure that it withstands the effects of wear,erosion, galling, corrosion and meets the requirements for cavitation, noiselevel etc. as specified in the data sheet, with prior approval from KOC.

8.3.9 Where specifically called for in the Data Sheet the internals of control valvesshall be hard faced to improve erosion resistance and reduce galling betweenmoving párts.

8.3.10 Control valves with soft seats shall only be employed when the specifieddegree of shut off cannot be achieved using metal seats.

8.3.11 Soft seated control valves shall be so designed that, upon any damage tothe soft seat, the leakage class of the valve is degraded only by one (1)

class, from the original ctass, by proper application of secondary metal-to-metal seat.

,l

DOC. NO. KOC-|-O1o of 35 REV.l

r/'

*

,f

4.4 Bonnet

The bonnet shall be bolted type with machined step for gasket retentionand guiding.

8.4.2 The bolting material shall be compat¡ble with the valve body, bonnet and

shall comply with the requirements of ASTM A193/ A32O for differenttemperature applications.

8.4.3 Where the temperature of the controlled fluid exceeds 230oC (45OoF),

bonnets with extension / fins shall be used to prevent extremetemperatures being transmitted to gland packing and actuators.

8.4.4 Valves to be provided with heat tracing, shall also use extended bonnets

8.4.5 For specified duties e.g. toxic, control valve stems should be bellowssealed, with an independent gland seal, the enclosed space being

monitored for bellows leakage. The materials used for bellows shall meetthe requirements of clause 7.1 as applicable.

8.5 Packinq Box Assemblv and Pe-cking Materials

8.5.1 Control valves shall be provided with a packing box assembly to preventleakage of process fluid past the valve stem.

8.5.2 The packing box assembly with packing flange, packing follower, lanternring, packing rings etc. shall be easily accessible for periodic adiustment.

8.5.3 The valves shall be drilled and tapped to accept a gland lubricator unlessotherwise specified.

8.5.4 The packing material shall withstand sudden change in operatingpressure, chemically ¡nert, elastic, easily deformable, fire resistant and be

suitable for the process application

8.5.5 The materiat used for packing shall be able to minimise friction and reducefugitive emissions to meet regulatory requirements.

8.5.6 lnterlocking self lubricating gland packing with spring followers shall be

used for valves on clean fluid application.

8.4.1

8.5.7

8.5.8

8.5.9

Braided packing shall be used on valves on higher temperature duties or

where chances of carbon or other deposits settl¡ng on the stem. ..

For services upto 230"C (4sQoFl, valve packing materials using P,TfE snall

be used.

Graphite laminated or performed ring pack¡ng

temperatures upto 5ffi" F).

be used for

DOC. NO. KOC-|-O1o of 35 REV.1

,r/"

*

zo,f

8.5.10 Any other latest mater¡al developed by manufacturers for packing withproven records shall be used with prior approval from KOC.

8.5.11 Asbestos shall not be used as a packing mater¡al.

8.6 Seat Leakage

8.6.1

8.6.2

The seat leakage class for a conûol valve shall be selected based on therequirement of how t¡ghtly the valve shouH shut off in service.

Valve Data Sheets shall state the maximum allowable seat leakage in

accordance with ANSI FCI-7O-Z, which can be tolerated for a specificapplication

8.6.3

8.6.4 Control valves to be installed on an intermittently operated systemconnected to a continuous process at the downstream end (such as Waterdraw-off, sump and other recovery services), control valves on exportends of facility, fuel gas services, discharge lines to flare etc. shall be

class Vl to meet tight shutoff {TSO) requirement unless otherwisespecified in the Data Sheet.

9.0 CONTROL VALVE ACTUATORS

9.1 General

9.1.1 The actuator shall be supplied together with the valve as an integral unh,unless otherwise specified.

9.1.2 The actuator shall be direct or reverse act¡ng according to the process

requirement.

9.1.3 The actuator shall be sized to meet control, shutoff, and valve leakagerequirements.

9.1.4 The actuator shall be able to overcome a minimum of 125o/o of the worstpredictable process and mechanical forces within the valve, inclusive of fluid

shutoff pressures, coking or solids, gland compression, stiction, friction and

all other expected forces.

9.1.5 lf back-flow protection is part of the valve service, the actuator shall be

designed for producing the required force to achieve the operation.'r'.

9.1.6 Sizing criteria for açtuat'ors for three-way valves shall be chosen to enable

the valve to operateacross a single port

against the worst maximum d differential pressure

Unless otherwise specified, the seat leakage class for conÛolfor norrnal operation shall be Class lV based on the values given inFCt-70-2.

valveANSI

of 35DOC. NO. KOC-|-oî0 REV.l

r{'

*

9.1.7 The actuator shall be sufficiently powerfulthat bench setting for achievementof specified leakage rate is not required.

9.1 .8 All control valves shall be provided with an indicating device to show theposition of the valve, whether under the action of theactuator or handwheel.

9.1.9 Valve position shall be indicated on a scale on the actuator yoke or bymarking on the stem of a rotary type valve.

9.1.10 Conüol valves for compressor anti-surge applications shall be fast actingglobe type, with actuators to meet the stroke timing, as specified in the Data

Sheet to meet the following:

full stroke time including pre-stroke dead time ;

valve throttle t¡me to reach desired position after a specified o/o changein l/P signal;

valve throttle time to intermediate position after a specified oó rampchange in l/P signal.

9.2 Diaphreom Actuatorq

a)

b)

c)

9.2.1

9.2.2

9.2.?

9.2.4

9.2.5

9.2.6

The. pneumatic diaphragm actuators shall be totally enclosed spring-returntype untess otherwise specified.

The spring shall be corrosion resistant having linear characteristic over thestem travel range, and shall have a readily accessible adjusting nut.

The yoke shall be of cast steel or ductile iron, adequately painted or platedagainst the environment.

The normal operating range of diaphragm valves shall be 0.2 to 1.0 barg(3 to 15 psig) and the maximum operating pressure shall not exceed4.O barg (60 psig), unless otherwise specified.

Reverse-acting diaphragm actuators shall be used only for thoseapplications, where the direct-act¡ng type of actuator is not suitable orspecifically called for in the Data Sheet.

Actuator failure mode must accomplish the valve fail positions. Therequired fail position of the valve shall be as specified on valve DataSheets. lt may be "Fail Open", "Fail Closed", or "Fail Locked i Hold".

/#*N

DOC. NO. KOC-|-o10 of 35 REV.l

,/-

*

9.3 Piston Actuators

9.3.1 Piston actuators shall be used, where long stroke or high thrust is

required for the operation of the control valve.

9.3.2 Double acting piston actuator shall be provided with an external volumetank and trip system to achieve the desired failure position.

9.3.3 The tank shall be provided with a drain valve, pressure gauge and reliefvalve.

9.3.4 Piston actuators shall be sized to supply the specified force using no more

than 5.0 bars (75 psig), but must be suitably rated for pressures up to8.5 bars (125 psig)

9.4 Hydraulic Actt¡ators

9.4.1 Where specificatly called for in the project document I Data Sheet, hydraulicactuator shall be provided along with a pneumatically driven pump to supplythe required hydraulic pressure for operation of the valve.

9.4.2

9.4.3

The drive medium for the pump could be either air or hydrocarbon gas as

specified. ln case of air driven pumps, the required air pressure shall notbe greater than 5 barg (75 psig).

Where the medium used is hydrocarbon gas, the material of constructionshall meet the requirements of NACE O175.

9.4.4 The actuator shall be provided with the following:

a) a separate hand-operated pump for manual operation;

selector switchesoperat¡on.

for remote/local mode and auto/open/close

9.5 Çelf Actuated.Control Valves

9.5.1 Where specifically called for in the P&lD/Data Sheet self actuated controlvalves shall be used for local, fixed gain control of utilities.

9.5.2 The actuator including the spring shall be suitable for the servicespecified.

9.5.3 For hydrocarbonlfuel gas services, the actuator shall be non-bleed typeand sealed. lf any bleed is inevitable, it shall be piped to a safe location.

b)

I o z

DOC. NO. KOC{-010 of 35 REV.1

r/"

*ô

o

9.5.4

9.6

The self-actuated valve shall not be used in the following applications:

a) where the down stream of self-actuated control valve is connectedto a pressure system i

b) for t¡ght shutoff applications;

c) sour gas and produced water services.

Electric Actuators

Where specifically called for in the project document/Data Sheet,electrically powered actuators suitable for the part¡cular service andcertified for using in the specified hazardous area shall be provided-

1O.0 CONTROL VALVE ACCESSORIES

1O.1 Valve Positioners

10.1.1 General

Where specified in the Data Sheet, the 'conÛol valves shall beprovided with valve positioners, to compare the valve stem positionwith the signal generated by the controller, and increase or decreasethe air pressure in the actuator until the correct stem position isobtained.

b) Valve positioners shall be designed to achieve the followingfunctions:

a)

t. reverse the valve action without changing the "fail safe"action of the spring in the actuator;

ilt.

iv.

V.

¡¡. modify the control valve flow characteristic;

increase the thrust in spring diaphragm actuators;

reduce hysteresis;

split range operat¡on (however use of positioner for splitrange is subject to KOC's approval on a case to case basis);

improve the resolution or sensitivity of the actuator wherehigh precision valve control is required

VI

DOC. NO. KOC-!-O1o of 35 REV.l

rl'

1O.1.2 Pneumatic Positioners

a) Pneumatic positioners shall be suitable for O.2 to 1.0 barg (3 to15psigl input signal, and the output shall be within the range O.2 to 1.0barg (3to15 psig), unless otherwise specified.

b) It shall be fitted w¡th 50 mm dial pressure gauges indicating the air

supply pressure, signal ¡nput pressure and the ouþut pressure to thevalve actuator.

Unless otherwise specified, the air connection to the positioners shall

be of size 1/4 NPT.

d) The positioner shall be reversible in the f¡eld, and shall be fullyadjustable for span.

e) The positioner shall be side mounted on globe valves, and be topmounted on quarter-turn valves. The pressure gauges for the topmounted positioner shall be provided with bottom connection.

A pneumatic bypass shall be fitted to all positioners for 0.2 to 1.0barg (3 to 15 psig) actuators, untess otherw¡se specified in the DataShoet.

s) Positioner cases shall be resistant to the environmental conditions and

the bleed port protected from wind-blown dust and sand.

h) All mechanical linkages, fastenings etc. shall be suitable for operationin the sandy environment and shall be of stainless steel material.

10.1.3 Electro-Pneumatic Positioner

Electro-pneumatic positioners shall be suitable for input signal of 4-2OmA.

The Electro-pneumatic positioners shall be provided with two 50 mmpressure gauges to display the air supply and output signal airpressure.

The positioner shall be certified for use in the hazardous area as

specified in the Data Sheet

1O.1.4 SmartPositioners

a) Smart positioners shall be of microprocessor based, using latesttechnology.

c)

f)

a)

b)

c)

ffi


ÕÉ

*

r/'

b) Positioners shall be suitable for an input signal of 4-2Q mA unless

otherwise specified.

c) lt shall have .facility for remote calibration, monitoring and

diagnostics.

d) The positioners shal! be certified for use in the hazardous area

specified in the Data Sheet.

1O.2 Air Lock-Up Kits

10.2.1 Air tock-up kits shall be mounted and piped on the valve, to hold the valveposition, in the event of plant air supply pressure falls below a certain level.

10.2.2 The lock-up relay shall detect low pressure downstream of the air set and

lock-in the air contained in the actuator. The system shall normally be self-

resetting.

10.3 Transducers

10.3.1 Electro-pneumatic transducers shall convert the electrical signals topneumatic signals in an electronic control toop, for providing input to thepneumatic actuators.

10.3.2 The Electro-Pneumatic Transducer shall be mounted adjacent toactuators.

10.3.3 The transducer shall be suitable for an input of 4-2OmA DC and theoutput shall be O.2 to 1 barg (3 to 15 psig) unless otherwise specified

10.3.4 The transducer shall be weatherproof and certified for the electrical area

classification as specified in the Data Sheet.

10.4 Handvy-heels

10.4.1 Handwheels shall be side mounted, lockable and linked in such a manner thatthe actuator can be removed when the handwheel is engaged.

10.4.2 The operationat force required for the handwheel shall not exceed 22O N at

the rim unless otherwise specified.

10.4.3

10.4.4

The handwheel shall be ergonomically designed and sized, so that thenumber of turns required to open or close the valve is minimum

ing is imp'rqctical orundesirable. ln such cases a suitably designedassigned to the removed unit.

lace shall be

DOC. NO. KOC-!-O1o of 35 REV.1

10.4.5 The handwheel shall be provided with a declutchable device to prevent

rotation when the motor is operating.

10.5 Limit Switches

10.5.1 Limit switches shall be of hermetically sealed proximity / mechanical type, as

specified in the Data Sheet.

10.5.2 The limit switch shall be supplied mounted in an enclosure sealed to lP 65 inaccordance with IEC-60529, certified for using in the hazardous area as

specified in the Data Sheet

10.5.3 The switch box, complete with internally adjustable switch actuators shall be

mounted on the valve yoke and shall be driven by stainless steel linkages and

shafts properly sealed for use in the sandy environment.

10.5.4 The limit switch shall be suitable for lugged termination of cable of minimumsize 2.5 mm2.

10.6 Air Filter Requlator Qets

10.6.1 Each valve or individual pneumatic instrument connected to the valve shallbe fitted with an air filter regulator set. This shall consist of an air regulatorwith suitable spring range, an integral filter, drain bowl and a 50 mm dial

output air pressure gauge.

10.6.2 The air filter regulator set shall be with a port size of 114 in. NPT, unlessotherwise specified. Spring adjustment shall be by means of stainless steelscrew and locknut.

1O.7 Solenoid Valves

10.7.1 Solenoid valves shall be direct act¡ng, spring return type of robustconstruction designed for industrial use. The coil and spring power shall be

selected to provide ample operational force to position the solenoid correctlyunder all applicable service conditions

10.7.2 The solenoid valves shall be suitable for continuous duty, with class-Hinsulated high temperature rated encapsulated coils.

10.7.3 The operating voltage shall be 1 10 V, 50 Hz AC unless otherwise specified.

10.7.4 The solenoid shall generally be factory mounted to the valve and where thisis not possible, it shall be tested with the valve. hooked up in a way thatclosely approximates the final installed situation. i':

10.7.5 Solenoids shall be dust and weather pro6os2e and namep,oor,kffiW"o.

of to ance with IEC-

Page 2O of 35DOC. NO. KOC-|-O1o REV.1

*rp

,/-

*

Þ7-

LLO

(,

10.8 Air Volume Booster Rejavs

10.8.1 An air-volume booster relay, that ampl¡fies the capacity of a control signaland improves the response of the control valve, shall be provided wherespecified in the Data Sheet

10.8.2 Volume booster relays shall be used in cases where the control valve is

located far away from its pneumatic controller, where the valve has a largepneumatic diaphragm and where fast valve response is required.

10.9 Mounting of Accessories

10.9.1 The installation arrangements for the valve shall be carefully reviewed beforedesigning the accessory rnounb to ensure that the completed system ¡saccessible for operation and maintenance in the installed position. Thefollowing accessories, as applicable shall be supplied as a fully mounted and

tested assembly unless otherwise specified:

a) pneumatic or EIP positioner ;

b) solenoid valves ;

c) limit switch sets, position transmitters;

d) handwheel;

e) lock-up kits.

10.9.2 Air filter regulator sets, backup reservoir and fail-safe kits shall normally be

tested with the valve but supplied loose for mounting adjacent to the valve,unless specifically called for in thé project document.

10,9.3 All piping and fittings on the valve and accessories shall be of stainless steelprovided with twin ferrule fittings. The size shall be 3/8 in. for power air

connection and 1 l4 in. tor signal connection unless otherwise specified.

10.9.4 All bleed ports of the valve accessories shall be installed in such a waythat the vents are tubed downward

1 1.O VALVE NOISE, FLASHING AND CAVITA.TION

I 1.1 Valve Noise

1 1 .'l .1 Control valve noise as a result of turbulent flow, cavitation ' and

mechanical vibration shall be assessed and tested in accordancei'.with therequirements of IEC 60534-8.

11.1.2 The manufacturer shall sùbmit valve noise calculations for KOC approval.

DOC. NO. KOC-|-O10 of 35 REV.l

*d.o

11.1.3 The maximum allowabte noise level at one (1) meter downstream and

one (1) meter from the pipe surface shall be 85 dBA unless otherwisespecified in the Data Sheet.

11.1.4 Noise reducing design based on source treatment incorporating multipath,multistage trim shall be used to limit ttre noise to the specified levels.

11.1.5 ln exceptional cases where the specified noise level cannot be achieved bysource treatment, noise reducing methods using path treatment shall be used

with prior approval from KOC.

11.2 Flashing aru! Cavitation

Valves used in flashing and cavitation services shall be specially designed forthese services. Valves of low recovery type, using frictional paths, multipleport cages, vortex flow or other methods of velocity and anti-cavitationcontrol shall be used to meet the requirement. The methods used to achievethe controlshall be approved by KOC.

11.2.1

L

11.2.2 Potential blockage of the trim shall be carefully considered for low recoveryvalves. Design appraisal by the manufacturer shall ensure that anyparticulates or sludge present in the process will not block the passages.

12.O SHUTDOWN VALVES

12.1 General

12.1.1 The Shutdown valves used for Emergency Shutdown (ESD) and processisolation, to stop uncontrolled release of flammable or toxic materials are

covered in this section.

12.1.2 Shutdown valves shall be double-seated ball valves where operatingconditions permit. These valves shall be designed for pipeline ratedpressure at each location with a minimum of ANSI class 3OO.

12.1.3 The shutdown valves shall be pneumatic/hydraulic driven, designed to be

fail-safe, with an adequate reservoir of air at each valve, to ensure valveoperat¡on to a plant "safe condition", when an electrical or instrument a¡r

failure occurs.

12.1.4 The shutdown vatve package shall have all the control and auxiliary itemsrequired for the operation of the valve, which includes; solenoid valves,limit switches for sending valve position índication and alarms to remotelocations, pushbuttons, position lndicator etc. as specified in the P&lD/Data Sheet. i'l

DOC. NO. KOC-|-010 of 35 REV.l

ffu

12.2.3 Shutdown valves used for emergency shutdown (liquid servicê) shall havea minimum of Class V shutoff requirement unless otherwise specified in

the Data Sheet.

12.2.4 lsolation valves for custody transfer metering applications shall be doubleseated type with both the seats being bubble tight (class Vl) . The valvesshall be provided with integral intermediate bleed for on-line integritytesting.

12.2.5 The design of the valve and actuator assembly shall ensure that anypressure release of process media (e.9., gland leakage) cannotcontaminate the instrument air or hydraulic fluid supply system.

12.3 Actuator for Shutdown Valves

12.3.1 Actuators shall normally be spring return piston type operating through ascotch yoke or gearbox for quarter-turn valves and diaphragm type whenglobe valves have been specified for shutdown duty.

12.3.2 Where the standard spring return system is not suitable due to return forceor closing speed restriction, a double-acting actuator shall be used.

12.3.3 The opening and closing time to meet the process requirement for a

part¡cu¡ar application shall be indicated in the Data Sheet.

12.3.4 The actuator shall be capable of driving the valve from fully open to fullyclosed and vice versa, within the time specified, against the maximumdifferential pressure acting across tho valve.

12.2 Seat Leakaqe

12.2.1

12.2.2

Valve Data Sheets shall state the seat leakage class required for a specificapplication.

Unless otherwise specified in the Data Sheet, the Shutdown valves usedon fuel isolation service ( gas turbine fuel supply, fired heater fuel gas

supply, etc.) shall have Class Vl shut off requirements.

12.3.5

12.3.6

As shutdown valves spend long periods without cycling, particular care shallbe taken to ensure that the actuators deliver sufficient force to fullyopen/close the valves at the extremities of operation when called upon b doso. Due regard shall be paid to the possibility of sticking and gummy depositson valves which are stationary for long periods.

The torque / linear force delivered by the ESD valve actuator at the.minimumair design pressure shall be at least doubþ the calculated force for the mostarduous condition or combination of conditions and any other restrictions

ons it shall beapplicable in the par.ticular application.minimum 1.5 times the calculated force

-.Ã

For non

DOC. NO. KOC-|-010 of 35 REV.1

rþ

*úo

12.3.7 All mechan¡cal components of the valve shall be so designed to have

sufficient strength to utilize the force developed by the actuator.

12.4 Air Reservoirs

12.4.1 The air required for the actuators shall be supplied from a dedicated reservoir

with suffic¡ent reserve capacity to enable three complete valve operation

cycles (unless otherwise specified in the Data Sheet) to ensure supply of air

in the event of main instrument air supply failure.

12.4.2 The air reservoir shall be designed to ASME Sec.Vlll, Div 1.

12.4.9 Air to each shutdown valve actuator shall be controlled by a normally

energised solenoid valve powered from the ESD control circuit. On loss ofpower to the solenoid, the air shall be exhausted thus causing the shutdownvalve to move to its predetermined safe position,

12.4.4 The supply to the reservoir shall incorporate filters and check valves toensure that the air supply for the ESD valve is retained durlng loss of general

air pressure.

12,4.5 Pressure gages shall be provided on the reserve'tank and the pneumatic

supply line.

12.4.6 Pressure switches shall be fitted to the reservoir and pneumatic supply line todetect and send alarm to DCS of a possible problem on the air supply.

12.4.7 The reservoir shall be provided with a drain cock and safety relief valve withthe relief directed away from the maintenance area.

12.5 Limit Switches

12.5.1 Limit switches shall be providèd to shut down or operate associatedequipment as per P&lD ,when the ESD valve either starts to move or has

completed its movement, and to send the valve position indication signalsand alarms to remote locations.

12.5.2 The limit switches shalt be of the type as detailed in clause 10.5 of thisStandard, but shall be flame proof certified Ex "d" in all cases.

12.6 Solenoid Valves

12.6.1 Solenoid valve shall be de-energize-to-trip / fail-safe with spring and coilselected for quick action to achieve the operation time specified.

12.6.2 Atl other details of solenoid valve shall be same as specified in clause1O.7 of this Standard.

zÆt$t'¡.

DOC. NO. KOC{-O1o of 35 REV.l

t/"

*

od.

12.7 Pushbutton Control

12.7.1 Open/Close control pushbutton with necessary indications shall beprovided at a safe location from the ESD valve for manual isolation of thevalve under emergency conditions.

12.7.2 The pushbutton shall be provided with a protective shroud to preventaccidental activation.

12.7.3 Provision shall be made to lock the pushbutton in the OFF position.

12.7.4 Where the pushbuttons are part of an automatic shutdown system, theaction, which they initiate, should latch the system so that the ESD valvedoes not return to its original position when the pushbutton is released.

12.8 Valve Position lndicators

The ESD valves shall be provided with a highly visible, impact-resistant,beacon-type, valve-position indicator.

13.O FIRE PROTECTION

1 3.1 Where specified in the Data Sheet, the control and shutdown valves shallbe fire-safe and tested in accordance with API 6FA/AP! 607 as applícable.

13.2 All shutdown valves in ESD service shall be fire-safe rated and tested.

13.3 Consideration should be given to the use of fusible plugs or similartechniques to ensure rapid actuation of ESD valves in case of a fire,regardless of any other fire detection system available in the vicinity ofthe valve.

13.4 The valves used for fuel isolation shall be located outside area of high firerisk or passive fire protection shall be provided as specified in the DataSheet.

13.5 Where specified in the Data Sheet, the control/shutdown valve, actuatorand accessories shall be provided with fireproofing using suitableenclosure or coating so that the valve shall continue its operation for thespecified duration when exposed to a petroleum fire.

a

of 35DOC. NO. KOC-|-010 REV.l

IÈ

,*

*

2Þ,r

€-o

14.O IDENTIFICATIONNAMEPLATES

14.1 klentification of Control and Shutdown Valves

All process control valves and shutdown valves shall have stainless steelname plates permanently fastened by stainless steel screws. preferably

mounted on the yoke assembly. The nameplate shall be marked in

accordance with MSS-SP 25, which shall include the following:

k)

valve serial nurnber;

valve model number;

equipment identification number (ElN)

body /trim material;

ANSI class rating ;

body / trim size;

max. Cv rating;

action "air to close" or "air to open";

valve opening/closing time;

failure action;

trim characteristic; *

stem travel in mm; *

m) actuator operat¡ng range . *

Applicable only for"process control valves.

ldentification of Valve Accessories

Each valve accessories shall be identified with a stainless steel nameplatepermanently fastened by stainless steel screws, which shall include thefollowing:

a) instrument tag number / equipment identification number (ElN);

Ì'l

b) manufacturers name, model and serial number;

a)

b)

c)

d)

e)

Í)

sl

h)

j)

¡)

*

14.2

c) hazardous area class¡fication and certification

-Ã


r/'o

<Èl¿

*

o

14.3

t5.o

15.1

lndication.of Direction of Flow

The direction of flow through the valve shall be clearly and indelibly marked

on the body, preferably by a cast on arrow or stamped plate.

PERFORMANCE INSPECTION AND TESTING REOUIREMENTS

General

1 5.1 .1 Al¡ items included in the supply shall be designed, manufactured,inspected and tested under the control of a documented OualityAssurance system, of which the general requirements are given in clause18.0 of this Standard.

15.1.2 The control valves shall be subjected to routine tests at themanufacturer's works as per relevant project specification in conformitywith IEC 60534-6. Any additional testing, if required, shall also be carriedout as and where specified.

15.1.3 No equipment shall be delivered until all applicable tests have been

successfully completed.

15.1.4 The documentary evidence of the test reports and certification shall be

submitted to KOC for acceptancel approval.

15.2 lnspection and Testing Plan

15.2.1 The inspection and test plan shall include the following items in addition tothose found necessary by the rnanufacturer to ensure the quality of theproduct:

check on all materials of construction by cross-comparing the goods,

the material test certificates and the Data Sheets and drawings;

check on the dimensions of the finished valves against the drawingsapproved by the KOC;

check on the completed valve and all accessories against the Data

Sheet and specification requirements;

check on the vatve failure position against the Data Sheet;

check on the valve plug travei against the approved Drawings;

check that the valve packing is in accordance with the Data',$heet and

specifications;

a)

b)

c)

d)

e)

f)

g) check on the valve nameplate data andthis specification and t[e Data Sheets and

with

DOC. NO. KOC{-O1o of 35 REV.1

r/-

r/-*

o

h) check on the valve and accessories painting and protection and

general su¡tab¡¡¡ty for the environment;

15.3 Valve Testinq

1 5.3.1 The performance tests shall include the following:

valve hydrostatic pressure test;

seat leakage test;

hysteres¡s check and response check;

prove that the actuator will open against the design fluid pressure ín

the case of flow over plug and quarter-turR valves; .

confirm valve speed of travel is in accordance with the Data Sheet,and check stroke linearity with increasing and decreasing input signal;

confirm the operation of solenoid, limit switches and other accessoriesas applicable.

15.4 Actuator Testinq

15.4.1 The actuator shall be tested in conjunction with the valve

15.4.2 The contol valve actuator diaphragm case shall be tested for leakages. Thetest shall be conducted at 3 barg (45 psig), or at a higher level at which theactuator is specified to operate. The test shall be successful if no leakage isdetected over a 3-minute period around the diaphragm case bolts, peripheryof the diaphragm and at the breathing side of the diaphragm.

15.4.3 For conûol valves with push-up actuators having packing at the shaft seal,

the leakage test shall be additionally applied around the shaft at severalpositions of stroke.

15.4.4 The actuator cases for shutdown valves shall be tested for leakage. The testshall be conducted at 10.2 barg (145 psig), or a higher level at which theactuator is specified to operate. The test shall be successful if no leakage isdetected over a 3-minute period.

15.5 Certification

All the certification for each valve or group of valves shall be collated'in a

dossier which shall be available at final inspection. The dossiqr shâll includethe following:

a) certificates for all material and mechanical 370;

a)

b)

c)

d)

e)

f)

DOC. NO. KOC-I-010 of 35 REV.1

*

zqIL

\bt)

b) details of heat treatment procedures followed to obtain the requiredmechan¡cal properties;

c) NDT certificates;

d) weld procedures and qualifications;

e) pressure test certif¡cate;

f) leakage test certificate;

g) valve and actuator performance test certificate;

hl f¡re test certificate;

i) hazardous area certificates.

16.0 ELECTBOMAGNETIC COMPATIBIL|JY AND RADIO FREOUENCYINTERFERENCE IRFII

All electronic equipment/components supplied shall be designed and

manufactured such that under normal operating conditions. the associatedsystem shall be unaffected by electromagnetic disturbances likely to beencountered and shall not radiate RFI which shall affect the normaloperation of other electronic devices.

The electronic equipment/components shall be electromagneticallycompatible with the power supply and all other items of the system and inaccsrdance with the requirements of IEC 6100O.

16.1

16.2

17.O

17.1

17.1 .1

EOUTPMENT lN HAZARDOUS AREA

General

All materials and lnstallation methods shall rneet the requirernents of definedhazard classification in accordance with the requirements of KOC Standardlor'¡Hazardous Area Classification" (KOC-G-O02).

17.1.2 When selecting the equipment to be installed in hazardous areas, it is

essential that the following be taken into consideration:

a) The zone classification of plant area.

The apparatus enclosure group.

The apparatus temperature classification.

b)

c)

a

DOC. NO. KOC{-010 il of 35 REV.1

d-

*

z,x

t-o

17.2

17.2.1

Hazardous Area Certification

All equipment to be installed in a hazardous area shall conform to therelevant parts of KOC Recommended Practice for Selection, lnstallationand Maintenance of Electrical Equipment in Hazardous Areas (KOC-E-

004).

17.2.2 The equipment to be installed in a hazardous area shall be certified foruse in those areas by a testing authority of an international recognition.The list of testing and certifying agencies acceptable to KOC are given in

KOC-E-OO4 Part-2.

17.2.3 The copies of relevant certification documents shall be submitted for KOC

review and approval.

18.O OUALITY ASSURANCE

It shall be ensured that all the equipment manufacturers are operating a

quality syqtem preferably based on ISO $OOO series of standards tosatisfy the requirements of this Standard. The manufacturer shalldemonstrate compliance by providing a copy of the accredited certificateor the manufacturer's quality manual. Verification of the manufacturer'squality system is normally part of the pre-qualification procedure, and istherefore not detailed in the core text of this Standard .

19.O PACKIN.G, MARKING AND DOCUMENTATION

1 9.1 The valve, actuators and accessories shall be packed in shipping cratesor cartons that shall be dust-tight, moisture-resistant to prevent damageto contents. The packing shall be clearly marked with purchase ordernumber and the instrument tag numbers.

19.2 All correspondence, drawings, catalogues, instruction manuals, Data

Sheets or any other written information shall be in the English language.ln case of dual languages, one language shall be English.

19,3 Alt dimensions. units of measurement, physical constants etc. shall be inSl units, unless otherwise specified.

19.4 The manufacturer's submittals shall include the following documents as aminimum:

a) Completed Data Sheet.

Valve /actuator assembly drawing (lf ordered together)

lnstallation, operation and maintenance instructions.

b)

cl

d) Type test/ Figutine test certificates.

DOC. NO. KOG{"Olo Page 3O of 35 REV.l

|}

rt

* ô

e) Hazardous area certification for various accessories.

f) Fire test certificate (as applicable ).

19.5 For further details on packing, rnarking and docurnentat¡on refer to KOC

Standard for Packing, Marking and Documentation" (KOC.G-004).

2O.O SPARE PARTS ANp MAINTFNANCE REOU.IREMENTS

2O.1 General

20.1.1 This section covers the description of various categories of spare parts tobe supplied. The actual scope and number of spares required shall be asper details covered in respective project specifications.

20.1.2 For details on spare parts and ma¡ntenance data, refer to the "KOC

Standard for Spare Parts and Maintenance Data " (KOC-G-009).

2O.2 ConstructionSpares-

The scope of supply shall include construct¡on spares sufficient for theequipment to be in fully installed and operable condition. lt shall be

ensured that all necessary construction spares are included in the basesupply quantities to account for underestimates and losses and breakageduring construction.

2O.3 CommissioninqSpargg

Commissioning spares shall include the following:

a) those items which may normally require feplacement duringcommissioning after equipment first-run checks (such as gasketsand seals)

b) commonly used parts such as fuses, lamps, fittings etc. as

applicable that may require replacement during fau¡t-f¡nding and

rectification.

items that are susceptible to an occasional failure fromconstruction damage or manufacturing error such âS, solenoidcoils, air- filter-regulator sets etc.

c)

of 35DOC. NO. KOC{-O1o REV.l

$

t

r/"

* o

2O.4 Ooeratinq Spares

The operating spares required for two years operation shall include thefollowing:

a) those items having an expected life of two years or less, orrequired to be replaced during normal ma¡ntenance of an item /system;

b) a percentage.of large quantity items where a failure of one or moreitems could result from use for two years or less;

c) items where a movement towards the failure mode is notrecognizable under normal maintenance reviews, requiring instantreplacement to maintain the plant in running condition, ê.9.,pressure gauges.

20.5 lnsurance Spares

lnsurance spares are those items with an extended expected life, but thedelivery time of which could cause serious plant shutdown delays if a

failure occurred, e.g. control /shutdown valve.


\@.

r{t

,]

*&o

Proiect

21.O APPENDIX.I DATA SHEET FOR CoNTBOIIúALVE No

0 reverse

mtn. max.

P¡pe Material 59

Éot-ft-(t

Oth€r Actuator Types E hydraulic E sslf actuatsd

60 DNo

10 r Total s6c

11 Process Fluid 62 o Throttle T¡m€ to Dss¡red Pos¡tion for Vo

JÍlr¡2IUo

ôott,u¡ooÉ,È

of12 Upstream Condition E liquid û vapour E gas 63 r Throttld T¡me to lntàrmediate Position for oÂ

't3BYes u

Un¡t 65 BsmartFlow Rate

ú,t¡¡2ItsttoÀ

18 T19 lnlêt

Pressu¡e Pv21 Critical Pressure Pc O Yes

74 DNo

76

-oE=u,ts

=25 Shutoff Press, Pl26 max.

27 O hold 7S80 Model8f t¡¡ì

ôõ25oo

29 Calc. min. Flow Coef valve O

31 MFR V

DirectionPressure Class Set MFR.

& 89

at,t¡¡aoanttl¡¡ooÉ,u¡Ío

3!¡ 90ìo=t¡lu,o

ooot¡¡

J

matl.'l K¡t

n tlTrim D Balanced O Unbalanced Haz. Area Certificates Reqd. O Yes I No

Plug matl. I 95 Fire-Safe Test Cert¡ficâtes Reqd. Ú Yes 0 No

Type of Guiding 96 Fire Proofing Reqd. O Yes O No

4 Guide / Seat t 97 {timo}

Trim Coating 98Compliance With o

Hard Facing Reqd. û Yes ú No

Fire Safe Rating Feqd. t YesTION AILS ON

1

Matl.

' Ref CONTROL VRemarks:

Seat

1.10

/ Class

ENo 99

Data Sheet No.

YES

chkd

DOC. NO. KOC-|-O10 of 35 REV.l

r/'

,/'*

Remarks:

Ref.No. Datâ No.

R

2

Appvd

Project

21.O APPENDIX-2 DATA SHEET FOR SHUTDOWN yALVE No,

3 Haz, Area classification 63o.E5oÀl¡¡J

Éto2l¡¡

o]t

4 54 De-energized5 ' ûClosed

J(ú,lr¡2ll¡(,

o.D!,u¡ooÉ.È

No.7 Line Size

57

10 tr Haz. Area1 60

12

14 fot-

=30t-

=f,

1 64

17 P

6719

691

Manufactur€r ú,o

Io=oI

0 Full2

777A

É,oJ

f2É

ENoTrim

3

/ Class0Yes ONo Valve I

36 Resistance to HIC OYes 0 85o=.LooÉ,q.t¡¡cE

.Required Actuator, & other accessories

Menufacturer O Yes nNo86

340

Air or42 of Air I Yes

Prêssurê

ú,ol-:to

9311,lll

(tEFÊ,u¡t,Fg,u¡t-

E Yes

9447

Reserve Tank with49 and Material / trYes t5 Time 98

99SPECIFICATIONMET IN FULL

YES NO.SEPARATE SHEET)

SHUTDOWN E TADate Rev. Prep.By

o


O

*

ACKNOWLEqGEMENT

This Standard has been approved by the Standards Technical Committee (STC)

consisting of the following:

The draft of this Standard has been circulated to the KOC User Teams for theirreview and responses were received from the following:

Mr. Abdulla AL-Abdul Salam ( Standards Team)Mr. Mohd. Emam ( lnsp. Team)Mr. S. Kumar ( Standards Team lDr. Mohammad llyas ( Standards Team )

Mr. Khalid S. Al-Al¡ ( Gen.Proj. Team )

Mr. Henry S. Hill ( Opns.Tech.Svcs. Team -S)

' ChairmanDeputy ChairmanSecretary/ MemberMemberMemberMember

oPERATTONS GROUP(SI

Team Leader (Opns.Tech.Svcs.-S)

OPERATIONS GROUPIEI

Team Leader (Opris.Tech.Svcs.-E)

oPERATIONS GROUP(WI

Team Leader (Opns.Tech.Svcs.-W)

SUPPORT SVCS. GROUP (S&E}

Team Leader (Proj - E)

pRrLLrNg oPNS. GFOUP

Team Leader (Drilling Svcs.)

DIVIDED ZONE-GROUP

Team Leader (Proj. Engg. & Facilities)

ENGINEERING GROUP

Team Leader (Design)Team Leader (Construct¡on)Team Leader (Gen.Proj)

MAJOR PROJECTS GROUP

Team l-eader (Major Proj. lll]Team Leader (Major Proj. lV)

EXPORT& MARINE OPNg=çROUP

Team Leader (Export Svcs.)

INDUSTRIAL SERVICES GROUP

Team Leader (Util¡t¡es)Team Leader (Central Workshop)

LOSS PREVENTION GROUP

Dr. Mohammad llyasMr. A.UnnikrishnanMr. Louis ThiagarajMr. G.Santhosh KumarMr. S.Chandrasekhar

(Standards Team)(Standards Team l(Maint.Team East)(lnspectionTeam) : Member(Opns.Tech.Svcs.Team-S) : Member

: Task Force Leader Tel No.61406: Author / Member Tel Nq.61633: Member Tel No.22416

No 61 25022122

Team Leader (Corrosion)Team Leader (HSE)

This KOC Standard for "Control and Shutdown Valves" (KOC-!-O1O, Rev. 1) has beenprepared by the Task Force (TF-l/02) comprising of the following members: -


a

,/"

KOC-I-010

Documents

Transcript of KOC-I-010