Specification_ROSS-1005_Rev_3_for_Full_Scale_Ball_Valves.docx

UNITED STATES AIR FORCE RESEARCH LABORATORY

SPECIFICATION NUMBER ROSS-1005

ENGINEERING SPECIFICATION for HIGH PRESSURE BALL VALVES

March 14th, 2016

REVISION 3

Contents

Revision History

High Pressure Ball Valves

1. Scope This specification defines requirements for high pressure (generally in excess of 3,000 psig) gas and liquid cryogenic and ambient temperature isolation ball valves used in liquid and gaseous oxygen, hydrogen, helium, and nitrogen propellant and pressurization systems, and hydrocarbon fuel systems. The valves will be used by the Air Force Research Laboratory (AFRL) located at Edwards Air Force Base, California. Contained herein are specific requirements for design, fabrication, inspection, testing and delivery of the valves. The valves and accessories shall perform satisfactorily under the conditions and operating parameters specified on the Data Sheets and herein.

This specification addresses both hand and remote operated ball valves.

The valve and its accessories furnished under this specification shall be designed, manufactured and tested in accordance with the latest revision of the applicable portions of the specifications listed herein. In the event of a conflict between the documents referenced and the contents of this specification, the contents of this specification shall be considered a superseding requirement. This specification does not require “code” stamped valves.

American National Standards Institute

American Society of Mechanical Engineers ASME B31.3 Process Piping ASME Code, Section V, Pressure Vessels, Nondestructive Examination ASME Code, Section VIII, Pressure Vessels, Division 1 ASME Code, Section IX, Welding and Brazing Qualifications Government Agencies

KSC-KTI-5210C

54000-GM30

Material Selection List for Oxygen Service John C. Stennis Space Center – Specification for Materials used in Liquid Oxygen and Gaseous Oxygen Service Exempt from Batch Testing Requirements

Industry

American Society for Testing and Materials

ASTM Standards Related to Flammability and Sensitivity of Materials in Oxygen- Enriched Atmospheres (Compilation of ASTM standards related to oxygen safety issues Sponsored by ASTM Committee G-4)

NFPA-70 National Electric Code

Factory Mutual (FM) Class S610

Underwriters Laboratories (UL) Standard 913

2.2 Contractor Responsibilities

The Contractor shall ensure that all sub tier suppliers of equipment, materials, and services are aware of and comply with the requirements of this specification.

Nothing in this specification shall be construed to relieve the Contractor of responsibility for complying with applicable codes and standards in force at the time of award of contract.

The equipment to be furnished hereunder consists of hand or remote operated full port, soft seated ball valves, accessories, spare parts, tools, and documentation as specified herein and on the data sheets. It is the intent of the Contracting Officer to acquire complete and operable valves to be installed in his facilities. If there are parts or components required to make the Contractor’s valves complete and operable and are not identified in this specification, the Contractor shall identify such items to the Contracting Officer prior to submitting a bid.

The equipment specified herein will be installed outdoors and shall operate satisfactorily under the following conditions:

Table 1 - AFRL Edwards Environment

Each valve and its accessories shall be in accordance with this specification and the data sheets. This specification establishes the engineering design criteria for complete workable valve assemblies which are capable of performing as specified herein.

The equipment to be furnished hereunder shall consist of the Contractor’s standard design that meets or exceeds the requirements of this specification. Materials shall be new, in accordance with the applicable ASTM material specification requirements, and free of all defects that would affect performance or service life of the equipment, or which would cause unsightly, flawed, or damaged appearance.

Ball valves shall be designed as standard class valves in accordance with ANSI B 16.34 and ASME B31.3. Valves shall be full port, soft seat or metal seat, ball type. The body (except for flanged end connections) and bonnet shall not be constructed by welding, nor shall there be welding of pressure containing parts. Valves 150 lbs and heavier shall be supplied with lifting lugs attached in such a way that when supported by the lugs the valve is in an upright, horizontal position with the actuator pointing up.

3.2.3 Design

The valves shall conform to the size, pressure rating, material and other design features specified on the applicable data sheets and as further specified herein.

1. The completed valve assembly including operator and accessories shall be integrally self-supporting and capable of operation in any orientation. If cryogenic valves have orientation limits, (e.g. the bonnet must be kept upright to maintain a gas pocket) then those limits/conditions shall be stated.

2. The valves may be used in liquid and/or gaseous oxygen, helium, hydrogen, nitrogen and hydrocarbon fuel service as specified on the data sheets. When bidding refer to the medium specified on the data sheet. The valves shall be furnished complete with the specified accessories and shall be suitable for all conditions specified herein and on the data sheets.

3. Remote operated valves shall be hydraulically or pneumatically actuated as noted on the data sheets. The double acting cylinder shall be fitted with a solenoid valve and open/close limit switches.

4. Remote operated valve full stroke time (open/close) shall be as specified on the data sheets. If necessary the Contractor shall provide speed control valves to adjust the open/close stroke times to the requirements listed on the data sheets.

5. [If Hydraulic Actuator Specified]: The power cylinder, at minimum hydraulic fluid pressure, shall provide, as a minimum 110% of the maximum turning force required when the valve is operated at its maximum design differential pressure. Hydraulic accumulators (or GN2) will be provided by the Contracting Officer to provide pressure to the valve actuators.

6. The valve manifolding shall be designed such that by de-energizing one or more solenoid valves, the valve will move to, and lock in, the electrical fail safe position indicated on the data sheets.

7. When pneumatic cylinder operators are specified, they shall be designed, fabricated, and tested to verify that they are leak tight and suitable for operation under the supply pressure conditions specified on the data sheets. Cylinder operators shall be double acting. Pneumatic cylinders shall utilize either a spring and/or air spring to ensure fail safe operation. Pneumatic actuator assemblies shall be constructed to retain the spring load during and after a fire that raises the temperature of the actuator materials to 1650F. All pneumatic actuators shall be capable of being pressurized with up to 150 psi GN2 (as specified on the data sheets). If the Contractor uses an actuator with a lower actuation pressure than that specified, the Contractor shall be responsible to provide the required pressure regulation and pressure relief valve for the actuator.

8. The power cylinder of all pneumatic operated actuators at minimum pneumatic fluid pressure shall provide, as a minimum, 110% of the maximum turning force required when the valve is operated at its maximum design differential pressure. Actuators shall operate with dry nitrogen gas.

9. N/A

10. N/A

11. Three complete sets of spare softgoods (e.g. seals, packing, soft seats etc.) shall be provided upon delivery of the hardware. Each set shall be precision cleaned, packaged and identified in accordance with provision of Sections 5.0 of this specification. Identification shall include the valve softgoods service identifier as part of valve number (e.g. ROV-3002).

12. N/A

13. N/A

14. The valves for cryogenics or GOX must not contain pockets that can trap gaseous oxygen and compress it during any valve operation.

15. All valves shall be designed and fabricated so that metal to metal frictional rubbing is minimized or eliminated. For any metal to metal surfaces included in the ball valve design, the Contractor shall take particular care to verify there is no galling.

16. The components shall be designed and fabricated to minimize accumulation of contaminants in pockets.

17. Cast valve bodies shall exhibit no surface porosity or inclusions that could trap contaminants.

18. Pressure ratings for the components are specified on individual data sheets.

19. Valves shall be equipped with a rugged stem position pointer and position indicator.

20. The Contractor shall supply the valves with the face-to-face dimensions as specified on the data sheets. The tolerance for these dimensions shall be ±0.125”. The dimensional tolerance for the offset between and connection centerlines is ±0.03125”. The dimensional tolerance for the perpendicularity of hub face to bore axial centerline is ±0.25.

21. All remote operated valves shall be equipped with a mechanical, spring or air spring assisted, double acting pneumatic or hydraulic (as specified on the data sheets) cylinder actuator for remote “open-close” valve positioning.

22. Flanged end connections shall be Grayloc hubs as specified on the data sheets.

23. The actuator assemblies shall also include all solenoid valves, tubing, and associated fittings necessary for proper operation. The tubing connections shall be MS or AN 37 degree flared.

1. Construction Materials shall be new and free from defects and imperfections. They shall retain satisfactory mechanical properties throughout the specified working temperature and pressure ranges.

2. Selection of other metallic parts for internal use in the valves is the responsibility of the Contractor. It is emphasized that extreme care shall be used in selecting materials for high pressure oxygen service due to the risk of ignition and subsequent burning. Care shall also be used in selecting materials for use in hydrogen service (if applicable) because of the susceptibility of certain materials to hydrogen embrittlement and corrosion. All materials to be used for valve internals shall be reviewed and approved by the Contracting Officer.

3. If “304 SS” is specified on the data sheet, Austenitic stainless steel type 304 per ASTM A182 Grade F304, A351 Grade CF8, A479-304 shall be. ASTM A182 Grade F316, A351 Grade CF8M, or A479-316 shall be used where “316 SS” is identified on the data sheets.

4. When specified, Nickel alloys (Monel 400) shall conform to ASTM B564.

5. All soft goods used in all valves shall be selected from KTI-5210C Kennedy Technical Instruction—Material Selection List for all Oxygen and Air Services, and 54000-GM30 John C. Stennis Space Center—Specification for Materials used in Liquid Oxygen and Gaseous Oxygen Service Exempt from Batch Testing Requirements (NOTE—even though valves may not be initially specified for oxygen service, the Contracting Officer requires that all valves meet the above requirement as valves are often substituted from the initially specified service to another service, including oxygen).All soft goods used in high pressure oxygen service shall be tested in accordance with ASTM G86 “Standard Test Method for Determining Ignition Sensitivity of Materials to Mechanical Impact in Pressurized Oxygen Environments”. A copy of the test report shall be provided to the Contracting Officer.

6. Actuator Materials shall consist of corrosion resistant steel. The limit switches, solenoid valves, tubing, tubing fittings and other actuator assembly accessories shall consist of corrosion resistant materials. The other external metallic materials of the actuator assembly shall consist of corrosion resistant alloys wherever practical. All carbon steel surfaces of the actuator assembly shall be painted with a coast of rust-inhibiting primer and finished with a topcoat of gray or blue Rust-Oleum No. 1724 or equal.

7. Valve Lubricants – Use either Krytox 240AC grease (it is not required to batch test this material in accordance with ASTM Test method G-86), or any other lubricant that is certified for oxygen service up to 8,500 psig by batch testing in accordance with ASTM Test method G-86.

8. The properties of the fluids (except hydrocarbons) used are shown for reference in Table 2.

Table 2 – Properties of System Fluids

3.2.6 Bolting Material

1 Bolts used in ambient service conditions shall be per ASTM A193 B8 either Class 1 or Class 2. Nuts shall be per ASTM A194 Grade 8.

2 Bolting used in cryogenic service shall be ASTM A320 GR B8 either Class 1 , as shown in ASME B31.3 Table A-2 “Design Stress Values for Bolting Materials”, and paragraph 309.2.1. Nuts shall be ASTM A194 GR 8.

3 All bolts and nuts used in fabrication of the valves shall be marked in accordance with the most stringent requirements of the referenced ASTM standard, i.e. any marking or identification of the bolts that is in addition to the minimum marking required shall be followed.

4 Bolts used in services with temperatures lower than 325 must be impact tested in accordance with ANSI B31.3, Paragraph 323.3, and a copy of the test results furnished with each lot of bolts.

3.2.7 Accessories

1 All accessories shall meet the requirements of NEC Class 1, Division 2, Group D unless otherwise specified on the data sheets..

2 The Contractor’s responsibilities for the valve actuator and accessories include:

(A) Two limit switches (to indicate open and closed positions) and their associated hardware shall be securely supported by the actuator. Limit switches shall have the following features:

i. Double pole/single throw or double pole/double throw

ii. Intrinsically safe with NEMA Class 4 Enclosure

iii. Mechanical type or Proximity

iv. The contacts shall be rated for 28 VDC

v. The contacts shall be rated for 0.5 amperes resistive

vi. The limit switches shall have a maximum current leakage of 5 mA in the off state.

vii. Electrical connectors shall be provided with a 6 inch minimum length lead wire

viii. The Contracting Officer may provide an intrinsically safe electrical circuit for the limit switches at our discretion..

(B) Proximity switches are preferred for the above specified limit switches provided all identified requirements are met

(C) [If Hydraulically actuated] The actuator shall use hydraulic fluid at 100F and 3000 psig. Fluid viscosity will be 220 SSU at 100F. Hydraulic fluid shall be ROYCO 782 Fire Resistant, Super Clean, Synthetic Hydrocarbon hydraulic fluid.

(D) Full stroke time is defined as the time from application of voltage to the solenoid valve to full open/close on the valve.

(E) Filters. Gas filter regulators where specified shall be furnished with the equipment. They shall be of the integral type with an output gage, filter and drip well. Gas filtration rating is 10 micron absolute particle size.

(F) Handwheels and handpumps, if noted on the data sheets, shall be top mounted and normally disengaged.

(G) Solenoid valves shall be rated for continuous duty and shall be furnished with Class H insulation suitable for an operating temperature of 180°F, shall have 18 in. leads, and shall be provided with a 1/2” NPT conduit electrical connection. Solenoid valve wiring shall be color coded and labeled.

(H) DC operation solenoid valves shall be rated for nominal 24-28 VDC operation and shall be capable of continuous operation at 20 to 30 VDC.

(I) Solenoids valves shall meet NEMA Class 7 requirements for explosion proof rating. All solenoids wiring shall be isolated from its body by 109 ohms minimum at 500 Volts dc.

3.2.8 Cleaning

(See AFRL Cleaning Specification 15022, 30 Dec 2013 for details) All wetted parts of all valves, except as noted below, shall be precision cleaned in accordance with IEST-STD-CC1246E acceptance criteria to the level specified on the data sheets (unless noted otherwise on the data sheets) and AFRL Specification 15022. The packing or stuffing box, packing, guide bushings or other components located in the packing box shall be precision cleaned as specified herein. Unless otherwise specified (as in 3.3.2.8 for post cleaning leak checks), all other testing and inspection shall be performed prior to precision cleaning. For valves with butt weld ends, the body shall not be cleaned. The actuator and other components shall be precision cleaned as called for on the data sheets. For butt weld end valves, the valve body and topworks shall be packaged and shipped separately.

Spare soft goods for the valves shall be precision cleaned to the same level as specified for the valve.

A cleaning certificate stating that the valve/softgoods have been cleaned in accordance to the referenced standard and specified level shall be provided for each valve.

All welding shall be performed in accordance with ASME B31.3. All personnel performing welding shall be qualified to ASME Boiler and Pressure Vessel Code Section IX. All Weld Procedure Specifications (WPS) and Procedure Qualifications Records (PQR) shall be reviewed and approved by the Contracting Officer prior to starting welding. Any other procedures (such as weld repairs) pertaining to welding, used by the Contractor during the execution of the work shall be submitted to and approved by the Contracting Officer prior to performing the subject work.

Note that ASME Section IX has special qualification requirements for weld procedures used in low temperature service.

For all SS pressure boundary welds, the ferrite number (FN) for completed welds shall not exceed 8. The Contractor shall use the GTAW method to perform all welding on all stainless steel pressure boundary systems. (For example, with 304/316 SS, the filler metal for GTAW welding would be Midalloy Grade ER316L, AWS/SFA:5.9, size 3/32”, w/ Ferrite Number of 3-5.)

It is HIGHLY recommended that the Contractor obtain FN readings for each weld pass and record the results to verify the correct FN value. It is REQUIRED that the Contractor obtain and report the FN value for ALL completed welds.

All personnel performing nondestructive testing shall be certified in accordance with American Society for Non-Destructive Testing ASNT-TC-1A, Qualification of NDT Personnel. All manufacturer’s procedures for cleaning, welding, heat treating, leak testing, NDT inspection and other Quality Assurance Activities related to the fabrication of the valves shall be forwarded to the Contracting Officer in advance for review and approval prior to performing the work

3.3.2 Acceptance Testing

The Contractor shall also perform the following acceptance tests.

1. Each valve, operator and all accessories shall be factory inspected, adjusted and tested by the Contractor before shipment.

2. All valves shall be given a hydrostatic shell test in accordance with ANSI B16.34. Upon request the Contractor shall provide a written test procedure identifying how the hydrostatic shell test shall be performed.

3. S leakage tests shall be performed on each completely assembled valve, with the valve having been closed by the operator, per ANSI/FCI 70-2as modified herein. The shutoff class for each valve is noted on the data sheets. Leakage rates shall be measured at both required pressure per ANSI/FCI 70-2 AND the maximum shutoff pressure drop across the valve. Prior to performing the leakage tests, each valve shall be cycled from full open to full closed 10 times at ambient pressure and temperature. Upon request the Contractor shall provide a written test procedure identifying how the seat leakage test shall be performed.

4. After shell and seat leakage tests, each valve shall be dried and cleaned in accordance with the requirements of this specification.

5. When position switches are specified, the applicable valves shall be cycled from full open to full closed and back to full open for verification of position switch function and setting and the ability of the operator to open and close the valve after the seat leakage test has been performed.

6. A valve/actuator stroke and performance test shall be performed on each valve. The test will check for items such as lack of stem binding, tightness of tube fittings and correct tube runs, proper valve movement, correct operation of limit switches. The valves open/close stroke times shall be measured and recorded. The test shall be conducted with 100 ft of Belden plenum cable 89418 or Contracting Officer approved equivalent.

7. When a failsafe mechanism is specified for a valve, a fail safe test shall be performed to verify the valve fails in the position indicated on the data sheets. This shall involve cutting electrical power to the valve and verifying the fail position. The results of the fail safe test for electrical cut-off shall be recorded for each valve.

8. For each valve a post cleaning leak test shall be performed to demonstrate the valve meets the specified level for seat leakage. After cleaning and complete assembly of the valve it shall undergo a seat leakage test in accordance with ANSI/FCI 70-2 using clean, dry GN2 as the test media. The Contractor is responsible to provide all necessary cleaned test fixtures and other cleaned hardware and test apparatus to effect the test. Upon request the Contractor shall provide a written test procedure identifying how the post cleaning seat leakage test shall be performed.

3.3.3 Tests After Installation

Field tests, as required, will be made at the expense of the Contracting Officer, except that the Contractor may, at the Contractor’s expense, furnish qualified personnel to witness such tests.

When the data sheet specifies Liquid Oxygen as the fluid medium, field tests shall be performed using liquid nitrogen. When the data sheet specifies Liquid Hydrogen as the fluid medium, field tests shall be performed using liquid hydrogenField tests shall be as follows:

Should these field tests indicate that the equipment does not meet the specified performance requirements attributable to the valves design or defects in the materials of manufacturing, the cost of corrective measures shall be borne by the Contractor until such time as tests demonstrate that the specified performance requirements have been met.

3.4 Identification

Each valve body shall have a permanently attached stainless steel nameplate. The nameplate shall be stamped with the following information:

· Valve Manufacturer

· Valve Model Number

· Valve Serial Number

· Valve Size

· Valve Pressure Rating

· Valve Flow Coefficient

· Valve Trim Type and Part Number

· Valve Service Identification and Tag Number (e.g., ROV 3002)

· Purchase Order Number

· Fluid Service

· Valve Body Material

· Close Off Rating An arrow indicating the direction of flow shall be cast in the valve body, or a stainless steel metal plate with an arrow embossed on it shall be permanently affixed to the valve body.

The valve actuator shall have permanently affixed stainless steel name plate indicating as a minimum:

· Manufacturer Model Number

· Valve Serial Number

· Valve Size

· Valve Service Identification and Tag Number (e.g., ROVxxxx)

· Operating Design Pressure

· Design Temperature

· Hydrostatic Test Pressure In addition to the permanently attached metal plate, each valve shall have a 304 SS metal identification tag stamped with the applicable tag and serial number as specified on the valve data sheets. The metal tag shall be attached to the yoke with Inconel safety wire.

Each valve shall have the casting/forging material lot heat number permanently (cast, etched, stamped, etc.) marked on the body of the valve for traceability to the material certifications..

3.5 Painting and Finishing

Stainless steel surfaces, threads, valve interior and internal operating mechanisms shall not be primed or painted. All external hardware items shall be stainless steel or shall be plated, painted, or anodized for corrosion protection. Nameplates and identification tags shall not be painted. All internal end external surfaces of valves and actuators shall be cleaned of all grit, mill scale, loose metal particles, weld spatter, slag, dirt and other foreign matter. All burrs shall be removed and sharp edges shall be eased.

All carbon steel surfaces (such as actuator assembly) shall be painted as specified in section 3.2.5 of this document.

3.6 Warranty

The Contractor shall guarantee that the equipment furnished conforms to the requirements set forth and to the specified Codes, Standards, and Regulations, and that all specified tests have been satisfactorily completed. Valves shall be warranted against defects in materials and workmanship for a period of one year after installation at the Contracting Officer’s facility.

3.7 Documentation

The Contractor shall provide drawings and documentation as required by the Contracting Officer. Detailed envelope engineering drawings specifying face-to- face dimensions, width, height, actuator size and angle, weight, and any other pertinent physical characteristics shall be provided to the Contracting Officer. The drawings shall include detailed information on bolt torque values and sequences for all valves, and a schematic indicating the electo-hydraulic or electro-pneumatic control configuration. The drawings shall be approved by the Contracting Officer prior to the start of fabrication of the valves. The Contractor shall also provide a parts list, bill of materials, welding details, material standards, codes, and assembly drawing(s), which shall be approved by the Contracting Officer.

Information about valve materials, operational data and sizing is included on the valve data sheets attached to this specification. The Contractor is responsible for complying with these data sheets. Any exceptions to this specification or the data sheets shall be noted in accordance with Section 6 “Exceptions to the Specification”.

The Contractor shall provide sizing calculations for each valve addressing, but not limited to, Cv values, flow rates, valve pressure recovery factor, cavitation or choked flow data, and actuator sizing data to the Contractor. The Contractor shall provide three copies of the maintenance and operation manual for each valve which shall include a recommended spare parts list. Each manual shall be clearly marked with the valve tag and serial number.

The Contractor is responsible for the performance of all examinations and inspections, as specified herein. The Contracting Officer, may witness certain aspects of fabrication and testing. The Contracting Officer will make a final inspection of the valves prior to cleaning. The Contractor shall notify the Contracting Officer a minimum of one week in advance of when the valves will be ready for inspection prior to cleaning. The Contracting Officer will notify the Contractor at least one week in advance of any intended inspections. The Contracting Officer may want to conduct quality audits to verify correct material usage, qualifications of procedures and personnel, record keeping and related quality activities. The Contracting Officer may wish to obtain photographs or video footage of the work at the Contractor’s facilities during inspections and audits.

4.2 Quality Assurance Program

The Contractor shall have a Quality Assurance Program that fulfills the requirements of ASME Section VIII, Division 2, Quality Control System Requirements.

4.3 Materials

Full chemical and physical analysis (Certified Material Test Reports [CMTRs]) shall be provided for pressure boundary materials and trim components for all valves. Any materials provided that are not supported by the appropriate certificates will be rejected. For pressure boundary materials it is required that the heat number from the CMTR be indelibly marked on the exterior surface of the material. The CMTRs shall indicate the valve tag and serial number (e.g. ROV-3002). A separate copy of the CMTR marked with the valve tag and serial number shall be provided for each valve.

4.4 Weld Inspection

All pressure retaining welds shall be 100% radiographically examined in accordance with ASME B31.3, Paragraph 344.5. Any welds that cannot be radiographed shall be 100% liquid penetrant or UT tested. Radiographic film and results of liquid penetrant tests shall be provided to the Contracting Officer.

Acceptance criteria shall be as specified for Normal Fluid Service, except that no interior weld protrusion shall be greater than 1/16”.

The Contractor shall measure and record the ferrite content of all welds. This measurement shall be included as part of the valve documentation package

5. Packaging See AFRL Specification 15022 for information on packaging with respect to cleanliness level.

All shipping containers shall have the manufacturer’s name and the valve tag number clearly marked on the exterior surface.

All exceptions to this specification and the data sheets must be clearly identified in the Contractors response to the bid package. All exceptions shall be addressed and dispositioned in writing by the Contracting Officer prior to the award of contract.

6.2 Deliverables

The following items are the deliverables and the delivery for each shall be as specified in the Contract Statement of Work:

· Valves, spare parts, softgoods, tools, other hardware items

· Welding Procedures, welding qualifications, test procedures, cleaning procedures, radiographic and liquid penetrant procedures, heat treatment procedures

· 1 Test results, radiographic film CMTRs, cleaning certificates, soft goods impact test results, weld ferrite content measurements

· Detailed Engineering Drawings, fabrication drawings, sizing calculations

· Maintenance and operational manuals with spare parts list 1 Test results include hydrostatic tests, leak tests, impact test results, valve/actuator performance tests, limit switch verification, and fail safe position tests. Only one set of radiographic film is required. This documentation shall be “bundled” or sorted by valve tag number. Each valve shall be provided with a complete set of documentation.