IGS-M-PL-02-1(3) Jul.
2010
APPROVED
IGSIranian Gas Standards
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PLUG VALVES size 2" to 24" part(1)
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Fax:(9821)-8131-5679 http://igs.nigc.ir/igs [email protected]
IGS-M-PL-02 NIGC July 2010
ADDENDUM : The following paragraph of IGS-M-PL-02 ,part 1,1387 ,(sub-clause 3.13) ,has been
replaced by attached table."Valve external surface shall be painting or coating as per
manufacture’s standard"
ABOVE GROUND PLUG VALVE
Primer coat Epoxy polyamide ,in accordance with SSPC 22 ,with a
min. thickness of(DFT ) of 70/m .
Intermediate coat Epoxy polyamide ,in accordance with SSPC 22 , with a
min. thickness of 140/m.
Two-component aliphatic polyurethane , in accordance
Top coat With MIL-C-83286 B ,or equivalent ,with min. thickness
(DFT) of 70/m.
Colour : white (RAL 9016)
BURIED PLUG VALVE
First option
Two-component liquid epoxy 1.Service temperature : -20° C to +60° C.
Coating in Accordance with 2.Thickness : class B (min. DFT 800/m).
EN 10289 3.Cutback at the ends : (100±10)mm.
Second option
Two-component Polyurethane 1.Service temperature : -20° C to +60° C.
Coating in Accordance with 2.Thickness : class A(min. DFT 800/m).
EN 10290 3.Cutback at the ends : (100±10)mm.
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IGS-M-PL-02 NIGC July 2010
Normative references.
1.SSPC-paint 22 : Epoxy polyamide paints (Primer ,Intermediate , Top coat).
(Editorial changes Sept.2000)
2.MIL-C-83286 B : Urethane , Aliphatic Isocyanate For Aerospace applications.
3.BS EN 10289 (200 2) : Steel tubes and fittings for onshore and offshore pipelines-
External liquid applied epoxy and epoxy-modified coatings.
4.BS EN 10290 , 2002 : Steel tubes and fittings for offshore and offshore pipelines-
External liquid applied polyurethane and polyurethane
modified coatings.
2
NIGC Oct.2008 IGS-M-PL-002-1(2)
FOREWORD
This standard cancels and replaces PLD 102, which has been technically revised, it
intended to be mainly used by all divisions of N.I.G.C., and has been prepared on
interpretation of recognized standards, technical documents, knowledge, backgrounds
and experiences in gas industries at national and international levels.
Iranian Gas Standards (IGS) are prepared, reviewed and amended by technical standard
committees within NIGC standardization division of research & technology management
and submitted to "the Standards council of NIGC" for approval.
Iranian Gas Standards (IGS) are subjected to revision , amendment or withdrawal , if
required , thus the latest edition of IGS shall be checked / inquired by NIGC users .
Any comments from concerned parties or individuals in IGS'S are welcomed.
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NIGC Oct.2008 IGS-M-PL-002-1(2)
TABLE OF CONTENT
T IT L E PAGE NO:
1.0 SCOPE 1
2.0 NORMETIVE REFERENCES 2
3.0 EDESIGN 3-4
4.0 MATERIAL 5
5.0 DOCUMENTATION 6
6.0 TABLE 1 7
7.0 DATA SHEET 8-9
8.0 APPENDIX 1: PERFORMANCE TESTING BY CYCLING METHOD. 9
9.0 APPENDIX 2: RADIOGRAPHY & MAGNETIC PARTICLE TESTING. 13
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NIGC Oct.2008 IGS-M-PL-002-1(2)
1.0. SCOPE
1.1 This standard covers the minimum requirements for carbon steel lubricated taper
plug valves in normal size of 2-24 inch for class rating of 150,300 and 600.
1.2 This standard covers valve for sweet natural gas concerning distribution,
transmission systems and compressor station services. The valve shall be suitable
for design temperature range from -290C to 600C , for sour gas clause 3.11 (current
standard) shall be followed.
1.3 Any points not covered by this standard shall be in accordance with
API 6 D, and ANSI /ASME B.16.34 (latest edition).
2.0. NORMETIVE REFERENCES :
- API 6 D: Petroleum and natural gas industries–pipeline transportation
systems – pipeline valves
- API 6 FA: Specification for fire test for valves
- ANSI/ASME B16.34: Valves – flanged threaded, and welding end
- ASME SEC.VIII: Boiler & pressure vessel code
- ASTM A 105: Standard specification for carbon steel forgings for pipeline
application
- ASTM A216: Standard specification for carbon steel casting, suitable for
fusion welding, for high temp. Service
- ANSI B. 16.5: Pipe flanged and flanged fittings NPS ½ through NPS 24
- ASTM A 193: Standard specification for alloy steel and stainless steel
bolting materials for high temp . Service
- ASTM A194: Standard specification for carbon and alloy steel nuts for
bolts for high pressure of high temp .Service or both
- MSS-SP-55: Quality standard for steel castings for valves, flanges , fitting,
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NIGC Oct.2008 IGS-M-PL-002-1(2)
and other piping components, visual method for evaluation of
surface integrity
3.0. DESIGN
3.1. Valves from 2 to 24 inch shall be in accordance with API 6 D and
ANSI/ASME B 16.34
3.2. Flanged ends valves shall be furnished with raised face and serriated
finish , flanges shall be integral with the body.
3.3. Unless otherwise specified, all lubricated taper plug valves must be of the
inverted plug "The pressure balance type"
3.4. When specified standard type (non-pressure balanced) are permitted only for
class 150 , up to 8 inch inclusive.
3.5. The port area shall be rectangular and meet the following :
- Regular pattern : Minimum 60 percent of valve end area .
- Short pattern : Minimum 40 percent of valve end area .
- Venturi pattern : Minimum 40 percent of valve end area .
3.6. Face to face and end to end dimensions shall be in accordance with API 6D
latest edition
3.7. Valves shall be fire safe in accordance with one of the following standards:
- API 6 FA
- B.S.6755 part2
3.8. Valves shall be designed to be able to accommodate a device for locking the
plug assembly in both open and closed position.
3.9. Valve shall be furnished with a position indicator , showing open position in
the direction of flow and close position perpendicular to direction of flow ,
the on/off marking shall be in English, easily visible and permanently
legible.
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NIGC Oct.2008 IGS-M-PL-002-1(2)
3.10. System sealing shall be designed for easy replacement while the valves is in
the open position, all valves stem seals shall be designed in order to
utilizing at least two separate independent stem seals wherein one seal is
replaceable without gas flow interruption or alternatively shall be
equipped with a facility for injection of secondary sealant
3.11. In the case of sour gas, all parts, material, welds, and heat effected zones
of welds exposed to line fluids shall meet the hardness, carbon equivalent
valve. (CEV) and heat treatment requirements as specified in ISO 15156
part 1, 2, 3 additional requirements should be specified by end user.
3.12. Design, Manufacturing. Dimension, testing and marking shall be all in
accordance with API 6D and ANSI /ASME B 16.34 latest edition.
3.13. Valve external surface painting or coating as per manufacturer's standard,
but details shall submitted.
3.14. Performance test and certificate shall be according to appendix 1, visual
examination, radiography and magnetic particle testing shall be according
to appendix 2.
4.0. MATERIAL :
Body, Bonnet, Cover ,ends: Cast carbon steel at least according to ASTM A216
Grade WCB/WCC or BS 1504 - 161 GRADE 430/480 or
forged carbon steel at least to ASTM a 105 or BS 1503
GRADE 221/550
Plug: Cast carbon steel at least according to ASTM A 216,
Grade WCB/WCC or BS 1504 – 161 GRADE 430/480, or
forged carbon steel to ASTM a 105 or BS 1503, grade
221/550
Plug surface shall have special treatment, electroless
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NIGC Oct.2008 IGS-M-PL-002-1(2)
nickel plated with minimum 25I thickness as per
ASTM B656 or hard chromium plated with minimum
25I thickness as per ASTM B 650, with or without
special type of PTFE as top layer, for ease of
operation and tightness.
Top layer thickness shall be specified by
manufacturer.
Stem: Forged carbon steel at least to ASTM A105 or BS 1503,
Grade 221/550 or alloy steel bar at least according to
AISI 4140 with hard chromium or electroless nickel
plating or special type of PTFE .
Non-metallic parts: Shall be made of suitable elastomer/ Plastomer
materials (such as PTFE, viton according to ASTM
D2004, HK 710 or ASTM D-145) .
5.0. DOCUMENTATION :
5.1. Required documents at the stage for technical evaluation:
- Up dated API 6 D monogram .
- Sectional drawing , with part- list materials.
- Original technical catalogue.
- Related data sheet.
- List of recommended spare parts.
- Packing procedure.
5.2. Required documents at stage of ordering:
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NIGC Oct.2008 IGS-M-PL-002-1(2)
- Four set of manufacturing drawing including list of material & technical
information.
- Operation maintenance manual.
METHOD OF OPERATION
Table 1
METHOD OF OPERATION
SIZE
(in) CLASS RATING CLASS RATING CLASS RATING
150 300 600
2 WRENCH WRENCH WRENCH
(1,2) (1,2) (1,2,3)
4 WRENCH WRENCH WRENCH
6 WRENCH WRENCH GEAR
8 GEAR GEAR GEAR
10 GEAR GEAR GEAR
12 GEAR GEAR GEAR
16 ----- GEAR GEAR
20 ------ GEAR/ACTUATOR GEAR/ACTUATOR
24 ------- GEAR/ACTUATOR GEAR/ACTUATOR
Notes:
1- Plug pattern
(1) : Short
(2) : Venturi
(3) : Regular
2- Gear box Specification shall be according to IGS-MS PL-009(0):2005 .
3- Stem extension & matching pipe shall be specified by client .
4-The length of the wrench shall be such that a force not exceeding 350N to be required to
operate the valve from either its open or close position under the maximum
differential pressure.
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NIGC Oct.2008 IGS-M-PL-002-1(2)
DATA SHEET
MANUFACTURER ENQUIRY NO:
REQUIRED SPECIFICATION:
GENERAL
ITEM NO QUANTITY
STANDARD TYPE PRESSURE BLANCE TYPE
SIZE CLASS
PORT AREA (RECTANGULAR) PERCENTAGE
STEM EXTENSION IF REQUIRED
NOT REQUIRED
LENGTH :
SERVICE TEMPERATURE
MIN : (0C) MAX: (0C)
END CONNECTION
FLANGED ENDS
R.F. YES NO S.F. YES NO
SIZE: PRESSURE CLASS:
ANSI B16.5
YES NO
WELDING ENDS END PREPARATION ASME B.31.8
YES NO
VALVE SPECIFICATION
MODEL
ANTI -BLOW OUT STEM
YES NO
FIRE SAFE DESIGN
YES NO
FIRE SAFE RELEVANT STANDARD
OPERATING TEMP RANGE -29OC TO 60OC
YES NO
ANTI STATIC DEVICE
YES NO
APPLICABLE TO SOUR GAS
YES NO
SEALANT INJECTION
STEM: YES NO PLUG: YES NO
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NIGC Oct.2008 IGS-M-PL-002-1(2)
WRENCH GEAR ACTUATOR
OPERATION
LOCKING DEVICE
YES NO
END TO END FACE TO RACE
OVERALL DIMENSION
(mm) (mm)
WEIGHT(kg)
REQUIRED DOCUMMENTATION
THE MANUFACTURER SHALL SUBMIT THE FOLLOWING DOCUMENTATION BELOW
FOLLOWING ORDERING
YES NO
NON - DESTRUCTIVE EXAMINATION (NDE) RECORD
NACE HARDNESS CERTIFICATION
NDT PROCEDURES
FIRE TEST CERTIFICATE
TYPE APPROVAL BY A RECOGNIZED CERTIFICATION BODY AGENCY
VALVE EXTERNAL SURFACE PAITING OR COATING
QUALITY PLAN
CYCLING TEST CERTIFICATE FROM INDEPENDENT & RECOGNIZED
CERTIFYING BODY
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NIGC Oct.2008 IGS-M-PL-002-1(2)
APPENDIX 1
PERFORMANCE TEST BY CYCLING METHOD :
Manufacturer shall submit the cycling test certificate from an independent & certifying
body.
- Required Number of cycle must be at least 10,000. times for valves from 2 to 24 in
- inch ,concerning checking the integrity of plug external coating.
- Required number of cycle must be at least 3,000. times for valves from 2 to 24
- Inch ,concerning checking the leak performance after cycle test.
- TEST PROCETURES SHALL BE AS FOLLOWS :
Introduction :
Performance test ( type test ) , shall be carried out in accordance with this Annex
by an authorized certifying body, as long as the design, manufacturing method
and material have not been changed, the issued certificate is valid.
1- Selection of sizes for type testing :
2-1. for valves from 2 to 24 in. , class 150,300,600, qualification of the range
shall be as follows :
Half of the largest produced size in each class rating.
2-2. If the cycle test has been carried out on a valve with higher class rating, the
other lower class rating at the same size range of same manufacturer is
acceptable.
2-3.Two samples shall be chosen, one for checking the integrity of plug external
coating (regardless of type of coating after 10,000 cycles , and one for
checking the leaking of the valve, after 3000 cycles.
2-4.The selected samples must meet all the requirements of IGS –M-PL-002(2),
Part 1.
2-5.Tthe chosen test valves port area shall be as per this IGS standard.
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NIGC Oct.2008 IGS-M-PL-002-1(2)
2-6. Selection of test samples shall be done by manufacturer.
3.Checking the integrity of plug external coating :
3-1. Prior to cycling test, all the requited tests as per IGS-M-PL-002 (1), shall be
carried out to make sure, the selected test valve meets all the requirements
of IGS standard.
3-2.Tthe selected valve shall be cycled for 10,000 times.
3-3.Tthe plug shall be cycled in body taper seat in original condition .
3-4.During the cycle test, after every 2000 cycles, the plug surface shall be
examined to verify the integrity of anti- friction coating of the plug.
3-5.Acceptance criteria:
After 10,000 cycles, the plug surface shall be visually examined, which not
more than 50% of plug anti- friction coating may de-scaled or worn.
3.6. Testing procedure for checking the integrity of plug external coating:
3-6-1. Every minute valve shall be opened & closed one time.
3-6-2.Tthe cycling speed shall be specified by certifying body.
3-6-3.If cycle test is carried out at manufacturer's works, all machinery,
instruments & programming of cycle test shall be evaluated approved
& recorded by certifying body.
3-6-4. The authorized certifying body must make sure the selected sample by
the manufacturer is produced in his own facility.
3-6-5. The sample shall be tested in ambient condition and within 20-30 0C
temp.
4.Checking the leaking phenomena after cycle test :
4-1. Prior to cycling test , all required tests as per IGS-M-PL-002(1) before
external coating of the valve body , shall be carried out & make sure ,
the selected valve for cycling test meets all requirements or IGS
standard .
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NIGC Oct.2008 IGS-M-PL-002-1(2)
4-2. the selected valve shall be cycled for 3000 times.
4-3. At the end of the test, valve shall be tested as per IGS standard & no
leaking is allowed.
4-4.Testing procedure:
4-4-1. Every minute valve shall be opened & closed one time.
4-4-2. In every 100 cycles (opened & closed) valve shall be re-lubricated.
4-4-3. Make sure , there is not any leak at end of every 100 cycles , before
re- lubricating the valve under test , the seat test ( as per API 6 D )
shall be carried out , no adjustment is permitted till end of 3000
cycles.
4-4-4.The cycling speed shall be specified by certifying body.
4-4-5. If cycle test is caring out at manufacturer's works, all machinery,
instruments & programming of cycle test shall be evaluated,
approved & recorded by certifying body.
4.4.6. The authorized certifying body must make sure the selected sample by
the manufacturer is produced in his own facility.
4-4.7.Tthe sample shall be tested in ambient condition & within 20-300C
temp.
5. The attached data sheet shall be filled, signed & stamped by authorized
certifying body & the manufacturer.
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NIGC Oct.2008 IGS-M-PL-002-1(2)
Date sheet
Performance test (cycle test)
Manufacturer's name and address
Certifying body's name and address
Test result details of samples as per Sample 1 Class Size (in) Port area Fig no
(integrity
API6D/IGS. and this annex. test)
Sample 2 Class Size (in) Port area Fig no
(leak test)
Overall comments of certifying
body as per this appendix and
API6D/IGS
Manufacturer.s authorized person Name Signature Stamp Date
Certifying body,s authorized person
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NIGC Oct.2008 IGS-M-PL-002-1(2)
APPENDIX 2
VISUAL , RADIOGRAPHY AND MAGNETIC PARTICLE EXAMINATION
VISUAL EXAMINATION:: Surface defect of casted body shall be checked in
accordance with MSS-SP-55
RADIOGRAPHY: 20% of each individual order of casted body valve
ends shall be 100 percent radiographed for a length of
50 mm or twice of end thickness , which ever is larger,
in accordance with ASTM E-94 and no defect
permitted.
MAGNETIC PARTICLE TESTING: All interior and exterior surface of cast steel body
shall be 100 percent magnetic particle tested in
accordance with ASME SECTION V and interpreted in
accordance with ASME section V11 DIV . 1
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