ESSAR STEEL LIMITED

4.6 MTPA INTEGRATED STEEL PLANT

HYTEMP - HOT DRI FEEDING SYSTEM SMP - I

TECHNICAL SPECIFICATION FOR CONTROL VALVES & ON/OFFVALVES

ESSAR ENGINEERING SERVICES LTD.

SPEC NO: 1018200204TSP35H002

JANUARY 2009

ESSAR STEEL LIMITED

TECHNICAL SPECIFICATION OF CONTROL VALVES FOR HOT DRI FEEDING SYSTEM SMP-1 1018 CAPEX PROJECT
ESSAR ENGINEERING SERVICES LIMITED

CONTENTS
1.0 PROJECT INFORMATION ............................................................................................................................2 2.0 SCOPE OF WORK ..........................................................................................................................................3 3.0 PRODUCTS .....................................................................................................................................................5 4.0 EXECUTION .................................................................................................................................................10 4.2 TESTS: ...........................................................................................................................................................10 5.0 GUARANTEE:...............................................................................................................................................11 6.0 DATA SHEET ...............................................................................................................................................12 7.0 BILL OF QUANTITY.....61

Prepared By Rajpal Lamba

Checked By N.K.Sharma

Approved By S.Surender

Concurred by R.S Panesar/Akshay Panchal

2008. ESSAR ENGINEERING SERVICES. All rights reserved.

Page 1 of 61

ESSAR STEEL LIMITED

TECHNICAL SPECIFICATION OF CONTROL VALVES FOR HOT DRI FEEDING SYSTEM SMP-1 1018 CAPEX PROJECT
ESSAR ENGINEERING SERVICES LIMITED

1.0

PROJECT INFORMATION Name of the Project Location : HYTEMP - HOT DRI Feeding System : Hazira, Gujarat

Temperature Mean yearly Temperature Maximum Absolute Temperature : 26.6 C : 45.6 C

Mean Yearly maximum daily Temperature : 42.3 C Mean Yearly minimum temperature : 10.9 C

Rainfall Maximum rainfall in 24 hours Avg. annual rainfall : 459mm : 1,203.5mm

Wind Predominant wind Direction Avg. speed : South to West : 12.2 Km/h

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ESSAR STEEL LIMITED

TECHNICAL SPECIFICATION OF CONTROL VALVES FOR HOT DRI FEEDING SYSTEM SMP-1 1018 CAPEX PROJECT
ESSAR ENGINEERING SERVICES LIMITED

2.0 2.1 2.1.1 2.1.2 2.1.3

SCOPE OF WORK Work included Design, fabricate, test and deliver control valves in accordance with this specifications. Conflicting information shall be brought to the attention of buyer. Provide one set of special tools, if other than standard tools are required to maintain or adjust the valve. When required by the material requisition or data sheets provide start up component for valve with velocity limiting trim. i.e. blind head, gaskets, seals etc., clearly marked with identification. Work not included Equipment unloading and storage at the job site. Field installation of equipment. Tubing and/or piping external to and not included as a standard part of the equipment. Connecting piping and flange connections. Instrument air required for operation General Requirements The control identified on the data sheets are used in general service application. Special trims required to prevent cavitations and reduce noise and erosion shall be provided when required. Provide noise attenuation features to ensure sound pressure level, as defined by OSHA standards, does not exceed 85 dBA at all operating conditions. Identify all valves that have predicted sound level greater than 80 dBA for bare pipe conditions. Paint the entire valve in accordance with manufacturers standard painting and coating procedure for surface above 343C, use manufacturers standard heat resistant coating. Vendor to submit painting and coating procedure along with bid for client approval. All quotations shall contain a statement that the items offered are in conformity with the enclosed Technical Specification and drawings and wherever any exception/

2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.3 2.3.1

2.3.2

2.3.3

2.3.4

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ESSAR STEEL LIMITED

TECHNICAL SPECIFICATION OF CONTROL VALVES FOR HOT DRI FEEDING SYSTEM SMP-1 1018 CAPEX PROJECT
ESSAR ENGINEERING SERVICES LIMITED

2.3.5 2.3.6

deviations are taken, reference must be made to definite parts of this specification and complete description given of each exception and reason thereof in a separate sheet. Vendor to provide proven track record for their offered valves. The Purchaser or any one or more authorized by him, shall have the right to visit contractors/sub-contractors premises to check the physical progress of work inspection, testing etc., of the contract items or any part thereof at any time during all stages of manufacture. The contractor shall extend all necessary facilities for carrying out such inspection and check of progress of work. Quality assurance Provide all the valves in accordance with ASME piping system, ASME section II part A, ASTM material specifications MSS SP-25, NEMA ICS6, ASME/ANSI 16.34, ASME/ANSI B16.5, ISA S75.19, ISA S75.01 NACE and ANSI/FCI 70-2 as applicable. Any additional requirements will be listed on data sheets and/or technical notes section of the material requisition. Use sellers standard procedures for heat treating, welding, and hard facing of valves internals if they do not conflict with code and material standards. Perform all non destructive examinations as required by the code. Where additional examinations are identified on data sheets, use the requirement and acceptance criteria of ANSI B16.34. Submittals This section contains typical information to be included on vendor drawings and data submittals. Document submittal requirements shall be in accordance with requirements specified in the material requisition and this specification. The typical information required by the drawing and data submitted will include the following: a) Valve size, ANSI class, end connection size and schedule. b) Overall dimension valve and actuator including end to end and clearance dimension for dismantling c) Weight of installed assembly and centre of gravity.
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2.4 2.4.1

2.4.2 2.4.3

2.5 2.5.1 2.5.2 2.5.3

2008. ESSAR ENGINEERING SERVICES. All rights reserved.

ESSAR STEEL LIMITED

TECHNICAL SPECIFICATION OF CONTROL VALVES FOR HOT DRI FEEDING SYSTEM SMP-1 1018 CAPEX PROJECT
ESSAR ENGINEERING SERVICES LIMITED

d) e) f) g) h) i) 2.5.4 2.5.5 2.5.6 2.5.7 2.5.8 2.5.9

Weight of valve and actuator separately. Flow direction. Restriction, if any, on valve orientation. Bolting torque of any critical component. Tag no. purchase order no. and item no. Location, size, and function of buyers electrical and pneumatic connections.

Provide completed valve data sheets. Provide composite instruction manuals covering storage, installation, operation, and maintenance of the valves and all the accessories supplied with the valves. Provide composite recommended spare parts list, with prices, for 2 years or longer. Provide valve and actuator sizing calculations. State the straight run piping required and all other features inherent in the sellers design such as thermal sleeves, pipe connections etc., Clearly designate on drawings or on a separate list, which components will be shipped loose for mounting and piping by the buyer in the field. Any items not to designate will be understood to be factory mounted, assembled, and connected. PRODUCTS VALVE ACCESSORIES: Limit Switches Refer to data sheet. Tube fittings Refer to data sheet. Valve Positioner (Pneumatic or Electro pneumatic) Manufacturer standard or as specified on data sheet. I/P transducers Refer to data sheet. All transducers shall be designed for use with the valve output. Air set Refer to data sheet. Filter only Refer to data sheet. Solenoid valves Refer to data sheet.

3.0 3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7

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ESSAR STEEL LIMITED

TECHNICAL SPECIFICATION OF CONTROL VALVES FOR HOT DRI FEEDING SYSTEM SMP-1 1018 CAPEX PROJECT
ESSAR ENGINEERING SERVICES LIMITED

3.2 3.2.1

MATERIALS:

Limit Precipitation hardened stainless steel to A- 564, Grade 630(17-4PH), Condition H-900, Double H-1150, H-1075 or cast equivalent. 3.2.2 The following are acceptable for Body and bonnet materials :( Other materials may be acceptable with the Buyers approval) a) Cast Carbon steel: A 216 WCB, A 352 LCB. b) Forged carbon steel: A 105. c) Cast Stainless Steel: A351, GradeCF8, CF8M, CF3M or CF3. d) Forged Stainless Steel: A182, Grade F304 or F316. e) Cast alloy Steel: Chrome-moly A 217 WC9, _C5. f) Cast 3- % Nickel Steel: A 352 Grade LC3. 3.2.3 Provide all austenitic stainless steel bodies and bonnets in the solution annealed, heat treated condition. During manufacturing, except for welding, do not heat austenitic stainless steel bodies and bonnets above 177 C (350F) unless given a full solution anneal at the material suppliers recommended temperature and holding period and the quenched in water from the solution heat treating temperature to below 427 C (800F) in less than 3 minutes. 3.2.4 Provide stainless steel tubing for control air of proper size and gauge for operating conditions. 3.3 VALVE BODY

3.3.1 Provide valves to ASME/ANSI B16.34. 3.3.2 Where required provide butt weld ends in accordance with the field weld end preparation and weld transition details attached to the material requisition and as specified on the data sheets. For flanged valves refer to data sheets. 3.3.3 If the valve is specified in the data sheets as being butt welded and the body material and mating pipe material would result in a dissimilar-metal field weld, weld-on and stress relieve and extensions for a similar metal field weld. Cut end straight of 2 inches (50 mm) and under and prepare for butt weld if over 2 inches (50 mm). Do not socket weld dissimilar metals of service temperature is above 121C (250 F).

2008. ESSAR ENGINEERING SERVICES. All rights reserved.

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ESSAR STEEL LIMITED

TECHNICAL SPECIFICATION OF CONTROL VALVES FOR HOT DRI FEEDING SYSTEM SMP-1 1018 CAPEX PROJECT
ESSAR ENGINEERING SERVICES LIMITED

3.4 3.4.1 3.4.2 3.4.3

VALVE BONNET Use same basic material as for valve body (e.g. for WCB body provide either forged or carbon steel bonnet dependent upon suppliers design.) Use sellers standard packing, if not otherwise specified on the valve data. Install after testing is completed and stem is cleaned and dried. Minimum friction, compatibility with the process fluid, compatibility with process pressure, chemical compatibility of the process fluid are to be taken into consideration while selection packing material and type When practical by design provide spiralwound, fiber filled body gaskets. Seller is responsible for providing materials, gaskets, and packing compatible with the process fluid. This includes any special cleaning, assembly or warning labels. Where a bellows seal is used for primary isolation, seller shall ensure that the bellows pressure boundary exceeds the fluid critical pressure or can vent back through the body on bonnet heating. Secondary pressure boundary shall meet same pressure. Class as valve bonnet. Double packing and leak off shall be provided to monitor integrity of primary seal. . live loading system shall be applied for packing loading system. TRIM

3.4.4 3.4.5

3.5

3.5.1 Provide trim designs and materials to meet conditions specified on data sheets. 3.5.2 Cage type guiding is preferred for valves in modulating service. Where port size is 3 inches(76 mm) or larger, do not provide contoured plugs if differential pressure is greater than 200 psi (13.75 bar) for flow up and 100 psi(6.9 bar) for flow down on spring diaphragm actuated valves. 3.5.3 Opposed jet impact design may be used for liquids only in modulating service with less than 500 psi (34.3 bars) drop and 6 inch or smaller port size. 3.5.4 within pressure/temperature limits and if suitable for application, resilient seat sealing is acceptable. Shield the resilient material from direct fluid impingement and retain within a metal seal which limits compression. 3.5.5 The minimum leakage class for each control valve shall be as specified on the data sheets. 3.5.6 Trim selection shall be such that the normal flow must be passed with 65 to 75% valve opening and maximum flow at 85 to 90 % opening.
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ESSAR STEEL LIMITED

TECHNICAL SPECIFICATION OF CONTROL VALVES FOR HOT DRI FEEDING SYSTEM SMP-1 1018 CAPEX PROJECT
ESSAR ENGINEERING SERVICES LIMITED

3.6 3.6.1

ACTUATOR:

Provide actuators of adequate size to control the valve from wide open, fully modulating to shutoff conditions without oscillation or hunting caused by fluidproduced disturbances. 3.6.2 Size pneumatic actuators in accordance with requirements specified on data sheet. Size all actuators to shut off against at least 110 % of maximum shutoff pressure differential, or 110 % of the maximum calculated fluid produced force, whichever is greater. 3.6.3 Provided hand wheels where identified on the data sheets. Limit force required at rim of hand wheel to 50 LBF (23 Kg) maximum (push pull) 3.6.4 Provide local travel indicator from open to close, including intermediate positions.

3.7 3.7.1 3.7.2 3.7.3 3.7.4 3.7.5

ACCESSORIES: Provide accessories where indicated on the valve data sheets, or as required to meet specified service. If applicable provide IP 65 electrical enclosure with minimum electrical conduit connection size of NPT. Provide bracket mounts for solenoid valves, air filter regulator, I/P valve positioners. Supply solenoid valve suitable for continuously energized operation. For specification of voltage/cycles refer to data sheet. Provide proximity switches to diagnose open, closed, or intermediate position, as requested in valve data sheet. Full closed proximity switch shall rest at no more than 5 % open, and full open limit switch shall reset at no less than 95 % open. Provide pneumatic accessories suitable for indoor and outdoor services, with minimum NPT connections. The pneumatic tubing shall be SS and of swage lock/ Parker (Alock type) make. Provide electro pneumatic positioner which is field adjustable for stroke and field reversible without additional parts. Supply with input, output and supply gauges.

3.7.6

3.7.7

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ESSAR STEEL LIMITED

TECHNICAL SPECIFICATION OF CONTROL VALVES FOR HOT DRI FEEDING SYSTEM SMP-1 1018 CAPEX PROJECT
ESSAR ENGINEERING SERVICES LIMITED

3.7.8 Provide air filter regulator as specified on the valve data sheet, which is capable of filtering and reducing pressure. Provide output gauge on air filter regulator. Refer data sheet for actual minimum pressure. 3.8 3.8.1 SIZING:

Size valves to ensure control is maintained when modulating between minimum and maximum flow rates. Size valve to pass 110% of maximum stated flow at the same pressure drop specified for maximum flow rate. Select trim approximate constant gain for flowing condition over a full control range. 3.8.2 Where reduce trim is required, provide reduced diameter or reduced flow area design only and not reduced or porting within a full sized gauge. 3.9 IDENTIFICATION:

3.9.1 Mark the valve body, either in cast form, stamping, stainless plate, or any combination, including at least the following. a) Manufacturers name or identification. b) Valve serial number. c) Body material, ANSI class and size. d) Flow direction arrow or equivalent. e) Trim material & form. f) Valve rated CV 3.9.2 Fasten manufacturers standard name plate to the actuator with at least the following: a) Manufacturers name. b) Actuator type and size. c) Serial number. d) Bench test.

2008. ESSAR ENGINEERING SERVICES. All rights reserved.

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ESSAR STEEL LIMITED

TECHNICAL SPECIFICATION OF CONTROL VALVES FOR HOT DRI FEEDING SYSTEM SMP-1 1018 CAPEX PROJECT
ESSAR ENGINEERING SERVICES LIMITED

4.0 4.1 4.1.1

EXECUTION DELIVERY, STORAGE AND HANDLING:

Perform final cleaning to remove undesirable foreign material. Limit cleaning agents and rinse water used in cleaning austenitic stainless steel to less than 250 mm end forced air dry. Valve in oxygen service require precision cleaning and packing to preserve cleanliness. 4.1.2 Seal ends of the entire valve with non metallic covers and pressure sensitive tap. On 3 end larger valves, wire capsule desiccant to inside of each cover before sealing. For smaller valve, enclose valves in moisture resistance sealed poly ethythene envelopes or containers with wire in desiccant. 4.1.3 For shipment, place valve in a box or crate suitable for protection during shipment ad storage after receipt at the job site. Provide purchase order number, valve tag number, weight and hoisting location on the box/carat. 4.1.4 The delivery of all the equipment covered under this specification shall be for Hazira steel plant, site stores at Hazira and as per the address and delivery schedule to suit commissioning of plant in 6 months from the date of placement of order. 4.1.5 Provide instruction manual for section 2.5.5 within each valve box/carat. Enclose in a water type envelope external to valve sealing membrane, readily accessible when the lid is removed. 4.2 4.2.1 TESTS: Perform hydrostatic shell test as per ISA S75.19. Valve component may be hydrostatically separately, provided the complete assembly is given leak test at the design pressure indicated on the valve data sheets. For dual rated vales, the leak test pressure is the design pressure of the outlet side of the valve. Perform seat leakage as per ANSI/FCI 70-2. Leakage class specified on the valve data sheet. Perform operability check by applying a simulated input signal verifying the correct operation of all the components. Perform fugitive emission test as per OSHA. Perform stroking time test. Stroke time will start with the initial signal.

4.2.2 4.2.3 4.2.4 4.2.5

2008. ESSAR ENGINEERING SERVICES. All rights reserved.

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ESSAR STEEL LIMITED

TECHNICAL SPECIFICATION OF CONTROL VALVES FOR HOT DRI FEEDING SYSTEM SMP-1 1018 CAPEX PROJECT
ESSAR ENGINEERING SERVICES LIMITED

4.2.6

Perform air actuator case external leakage test at the sellers rated pressure + 5 psi. any evidence of leakage is unacceptable.

5.0 5.1

GUARANTEE: The instrument/equipment to be supplied under this specification shall meet the guaranteed performance specified in the enclosed data sheet/specification when operating the rated/specified conditions. The acceptance of the instrument /equipment shall be subject to satisfying these parameters during shop test at vendors works and or at site installation in complete assembled condition. All Control Valves shall be guaranteed against defective workmanship, materials and design for a period of 12 months from the date of installed acceptance by Purchaser or 18 months from date of shipment, whichever is shorter. If within the above period of time instrument furnished fail to meet guaranteed performance or develop defects due to faulty workmanship or materials, vendor shall repair or replace the same when requested by, and at no cost to, owners representative such repair or replacement shall include the cost of removing equipment from their installed location if necessary to gain access for correcting defects.

5.2

5.3

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TECHNICAL SPECIFICATION OF CONTROL VALVES FOR HOT DRI FEEDING SYSTEM SMP-1 1018 CAPEX PROJECT
ESSAR ENGINEERING SERVICES LIMITED

BILL OF QUANTITY:
SL NO. 1. 2. 3. 4. 5. DESCRIPTION CONTROL VALVES(BALL TYPE) CONTROL VALVES(GLOBE TYPE) CONTROL VALVES(BUTTERFLY TYPE) CONTROL VALVE(SHUT- OFF) QUANTITY 7 8 4 30 REMARKS

TOTAL

49

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