ASME boiler and pressure vessel code, Section IX: Qualification standard for welding and brazing procedures, welders, brazers and welding and brazing procedures.MATERIALS, EXAMINATION AND CERTIFICATION REQUIREMENTS FOR VALVES IN GENERAL SERVICES 1).1. INTRODUCTION 1.1 SCOPEThis document contains requirements for materials, examination, repair and certification of valves in general services. This specification shall be read in conjunction with the requirements of the relevant material specifications (e.g. the ASTM specifications) and the MESC specifications for the particular types of valves.NOTES:1. General service valves are used in any PED fluid group 2 (gas and liquid) services,including steam, classified in PED conformity assessment categories SEP, I, II and III (ref. PED directives 97/23/EC, articles 9, 10, WPG guidelines 1/8, 1/15 and annex II). General services are services not classed as "special service" in MESC specification SPE 77/303.2. Special service valves are used in (dangerous/hazardous) PED fluid group 1 (gas andliquid) services classified in PED conformity assessment categories III and IV (ref. PED directives 97/23/EC, articles 9, 10, WPG guidelines 1/8, 1/15 and annex II). Safety accessories are classified in category IV.1.2Valve brands, types and styles shall be accepted by Shell Global Solutions International B.V. (Shell-GSI) and listed in the Shell-GSI Technical Accepted Manufacturers And Products (TAMAP) database.1.3Valves that are not yet accepted by Shell-GSI, and therefore not listed in theShell-GSI TAMAP database, shall be prototype tested in accordance with the relevant Shell-GSI requirements and specifications.1.4Foundries and forge masters shall be evaluated and qualified by the valve manufacturer. Shell-GSI may request audit reports and other evidence to ensure cast and forged materials are meeting our acceptance criteria.1.5Valve manufacturers and their sub suppliers shall have ISO 9000 series quality system certification. Valve manufacturers of ISO 14313 and API 6D valve standards shall be licensed to use the API monogram.2. REFERENCES 2.1.In this specification reference is made to the following publications:NOTE:Unless specifically designated by date, the latest edition of each publication shall be used, together with any amendments/supplements/revisions thereto.ISO 14313 API 6D Specification for pipeline valves (gate, ball and check valves) ASME B16.34 Valves, flanged, threaded and welding end.ASME Section IXASTM A 105Specification for forging, carbon steel, for piping components.ASTM A 182 Forged or rolled alloy-steel pipe flanges, forged fittings, valves and parts for high temperature service.ASTM A 216 Steel castings, carbon, suitable for fusion welding, hightemperature service.ASTM A 217 Steel castings, martensitic stainless and alloy, for pressurecontaining parts, suitable for high temperature service.ASTM A 262 Standard Practices for detecting susceptibility to intergranularattack in austenitic stainless steels.ASTM A 336 Specification for alloy steel forging for pressure and hightemperature parts.ASTM A 350 Specification for forging, carbon and low-alloy steel, requiring notch toughness testing for piping components.ASTM A 351 Specification for steel castings, austenitic, austenitic-ferritic(Duplex) for pressure containing parts.ASTM A 352 Steel castings, ferritic and martensitic, for pressure containingparts, suitable for low temperature service.ASTM A370 Standard test methods and definitions for mechanical testing ofsteel products.ASTM A 494 Specification for castings, nickel and nickel alloy.ASTM A 516 Specification for pressure vessel plates, carbon steel, formoderate-and lower temperature service.ASTM A 744 Standard specification for castings, iron-chromium-nickel, corrosion resistant for severe service.ASTM A 890 Specification for castings, iron-chromium-nickel-molybdenumcorrosion resistant, Duplex (austenitic-ferritic) for generalapplication.ASTM B 150 Specification for aluminium bronze rod, bar and shapes.ASTM G28 Standard test methods of detecting susceptibility tointergranular corrosion in wrought, nickel-rich, chromium-bearing alloys.EN 10204 Metallic products – types of inspection documents.ISO 148 Steel – Charpy impact test (V-notch).ISO 9000 Quality management system requirements.ISO 10474 Steel and steel products - inspection documents.ISO 14313 Petroleum and natural gas industries – Pipeline transportationsystems – Pipeline valves.MSS SP-55 Quality standard (visual method) for steel castings for valves,flanges and fittings and piping.NACE MR 0175 (Edition 2002)Standard material requirements; Metals for sulphide stress cracking and stress corrosion cracking resistance in sour oilfield environments.PED 97/23/EC Pressure Equipment Directive, 97/23/ECSTOOMWEZEN Rules for pressure vessels.3. MATERIALSREQUIREMENTS3.1 CHEMICALCOMPOSITION3.1.1 BasematerialsFor the materials mentioned below, the following restrictions in chemical compositionshall apply:Material grade Additional restrictionsASTM A105 Carbon content shall be 0.23% weightmaximum.Carbon equivalent (CE) shall be 0.43% weightmaximum.ASTM A516 grades 60 and 65ASTM A216 grade WCB Carbon content shall be 0.25% weight maximumASTM A350 grade LF2 class 1 and 2 Carbon equivalent (CE) shall be 0.43% weight maximum and shall be determined by the formula mentioned previously.ASTM A352 grade LCC Manganese content shall be 1.30% maximum ASTM A182 grades F316 UNSS316000.Carbon content shall be 0.03% weight maximumASTM A351-CF8M andASTM A351-CF3M(Ref. Note 1)Carbon content shall be 0.03% weight maximumASTM A182 grade F51; and Duplex stainless steel UNS S31803 Nitrogen content shall be 0.15% weight minimumASTM B 150 grade UNS C63200 Aluminium content shall be 8.50% weightminimum and 10% weight maximumThe carbon equivalent (CE) shall be determined by the formula as mentioned below:CE= C + Mn/6 + (Cr+Mo+V)/5 + (Ni+Cu)/153.2 HEATTREATMENT3.2.1 The Cr-Mo steels to ASTM A 182 grade F5a, F9, F11 class 2, ASTM A 182 grade F22class 3, ASTM A 217 grade WC6 and ASTM A 217 grade WC9 shall be furnished in thenormalised and tempered condition.3.2.2 Austenitic/ferritic(duplex) stainless steel UNS S31803UNS S31803 materials (including castings) shall be solution annealed between 1020ºCand 1100ºC, followed by rapid quench, after all forming operations.Repair welding of UNS S31803 castings shall be in accordance with the requirements ofASTM A744 Paragraph 10.3.2.3 Austenitic stainless steel forging to ASTM A182 and ASTM A336 andcasting to ASTM A351.All austenitic stainless steels shall be supplied in the solution heat treated condition.For non-stabilized grades with a carbon content larger than 0.03% solution annealingshall be repeated after any welding.3.2.4 Austenitic Steel Forgings to ASTM A182 grades F321 and F347If specified in the relevant MESC description a stabilising heat treatment shall beperformed between 900ºC and 950ºC for two hours, followed by cooling in still air. Thisshall be applied after the solution heat treatment and again after any welding.3.2.5 Nickel alloy castings to ASTM A494 grade N-7MNickel alloy castings to ASTM A494 grade N-7M shall be solution annealed at 1180 ºC+/- 10 ºC. Annealing at other temperatures can be accepted provided qualification testsshow that this leads to a fully solution annealed structure which is free of precipitates.Castings to ASTM A494 N-7M shall be post-weld heat treated following weld repairsusing the same solution annealing procedure as used earlier.3.2.6 Carbon steel and alloy 400:3.2.6.1 If welding is applied on valve parts made of Alloy 400, they shall be Post Weld HeatTreated (PWHT) at 590 ºC for at least 1 hour.3.2.6.2 All repair welds in carbon steel and Alloy-400 material shall be PWHT at 590 ºC for atleast 1 hour per 25 mm thickness, followed by X-ray re-examination.3.2.7 All heat treatment procedures shall be subject to statistical process control to ensure thatthe final material properties comply with the material standard and this specification. Theprocess control data and related periodic quality control checks shall be documented.3.3 HARDNESSIf wet H2S or sour service conditions are specified, the hardness requirements ofNACE MR 0175 Edition 2002 shall apply for any process-wetted part of the valve andpressure-retaining bolting.For all other (non-NACE MR 0175) services the maximum allowable hardness shall be:Base metal, welds and heat affected zones of pressure containing parts 248 HV10Base metal of internals with weld deposits or hard facings 400 HV1013% chromium steel internals 400 HV10Hardness indentations shall be avoided on any sealing or sliding surfaces.TESTING3.4 IMPACTImpact testing is required for:-Cr-Mo steels to ASTM A 182 grade F11 class 2, ASTM A 182 grade F22 class 3, ASTMA 217 grade WC6 and ASTM A 217 grade WC9 if the thickness of any section of thesematerials is greater than 50 mm.-Low temperature carbon steel to ASTM A352 grade LCC-Carbon manganese forging to ASTM A350 grade LF2, class 1-fine grained C-Mn steels to ASTM A 516 grades 60 and 65- Austenitic/ferritic duplex 22%Cr stainless steels to ASTM A351 grades CH10, CH 20and CE8MN and ASTM A 890 grade 4A and the 25 % Cr duplex stainless steels toASTM A890 grades 5A and 6A.- Martensitic stainless steel to ASTM A182-F6NM.For low temperature carbon steel valves the notched bar impact test shall be performed,in accordance with the applicable ASTM standard, at a temperature of minus 50degrees Celsius with an average energy value of 26 joules minimum for 2 and anyof 3 specimens and 22 joules minimum for the single specimen.Where welding is perfomed on austenitic stainless steel forgings to ASTM A182and castings to ASTM A351 as part of the valve assembly, having a minimumdesign temperature of <-29°C, welding procedures shall be qualified by impacttesting at the minimum design temperature specified in accordance with therequirements in ASME B31.3, section 323.22.In addition to these requirements as stated in API RP582 section 6.3.2, all weldsshall have a ferrite number for the weld material not exceeding 8FN.For all other materials the impact tests shall be performed on test pieces from the sameheat as the valve body and which have been simultaneously subjected to the same heattreatment.The test temperature shall be for:-Cr-Mo valves (thickness > 50 mm): +20ºC and-Duplex stainless steels: minus 50ºCThe test specimens of forged/wrought material shall be taken in the transversedirection at 1/4 and 1/2 of the thickness. Castings shall have one set of impacts takenfrom a test block of the same melt and heat treatment batch.For each section, three tests shall be performed and the resulting Charpy-V notchenergy impact values shall be for:-Cr-Mo steels: 55 joules average, 48 joules minimum for single specimen-Duplex stainless steels: 40 joules average, 31 joules minimum for single specimenNote: On the impact testing requirements of Cr-Mo and Duplex, these are additionalrequirements due to the fact that there are no limits set for these materials in the ASTMstandard and therefore no reference can be made to a specific ASTM standard.TESTING3.5 CORROSION3.5.1 For austenitic stainless steels (AISI 201, 202, 301, 304H, 316, 316H, 317, 317L, 321and 347) and austenitic/ferritic (duplex) stainless steels the statistical process control,mentioned in section 3.2.8, shall include inter granular corrosion testing in accordancewith ASTM A 262, Practice E.Tested specimens shall reveal no signs of inter-granular corrosion.3.5.2 For austenitic stainless steels (AISI 304, 304L, CF3, CF8) and UNS N08028 thestatistical process control, mentioned in section 3.2.8, shall include inter granularcorrosion testing in accordance with ASTM A 262, Practice C and shall result in anaverage corrosion rate of no more than 0.3 mm per annum.3.5.3 For wrought Nickel-Rich, Chromium-Bearing alloys (UNS N06007, N06022, N06030,N06059, N06200, N06455, N06600, N06625, N06686, N06985, N08020, N08367,N08800, N08825, N10276) the statistical process control, mentioned in section3.2.8, shall include inter granular corrosion testing in accordance with ASTM G28method A.3.5.4 For other materials (not listed in ASTM A 262 and ASTM G 28) where inter granularcorrosion could be of concern (e.g., cast nickel-rich, chromium-bearing alloys) thestatistical process control, mentioned in section 3.2.8, shall include inter granularcorrosion testing with a relevant test. The procedure and acceptance criteria shallbe submitted to the Principal for approval.4. NON-DESTRUCTIVE EXAMINATION (NDE)4.1 Regardless of the sampling specified in section 4.2.1, a prototype casting shall be (orshall have been) fully inspected and tested by the manufacturer in accordance with thespecified acceptance criteria. In addition to the NDE specified in table 1, the prototypecasting shall be (or shall have been) radio-graphed (Ref. 4.2.5 note 5) in accordance withASME B16.34 section 8, with 100% full coverage of the casting. Acceptance level shallbe based on the requirements of ASME B16.34 annex B.4.2 NDE extent (sampling), methods and acceptance criteria shall be in accordance with thevalve design code and sections 4.2 and 4.3 of this MESC additional requirement.4.2.1 The valves on an order shall be separated into inspection lots.For valves produced by the same manufacturer a different lot is applicable for each ofthe following:- valve type (gate, globe, check, etc.)- valve body basic material type (carbon steel, LTCS, ferritic alloy, austenitic alloy,non-ferrous alloy, ferritic ductile iron, non-ferrous alloy)- quantity per heat batch (produced by the foundry) or heat treatment batch,whatever gives the biggest lot size.Each inspection lot shall be further divided into categories A and B as specified below:ACategoryASME rating: classes 150, 300, 600 All sizesBCategoryASME rating: classes 800, 900,All sizes1500, 1500 special class & 25004.2.2 From each inspection lot, percentage samples shall be taken in accordance with table 1,with a minimum of one valve per lot (which shall be the largest valve in that lot).4.2.3 A lot shall be accepted if all the samples of the lot meet the specified acceptance criteria.4.2.4 If any of the samples fails to meet the acceptance criteria, additional samples equal tothe original number shall be inspected.If these samples meet the acceptance criteria, the lot shall be accepted with theexception of the initially rejected items. If any of the additionally inspected samples failsto meet the acceptance criteria, then 100% of the lot shall be inspected or, at theprincipal's discretion, the entire lot shall be rejected.4.2.5 A sampling and inspection scheme shall be submitted to the principal.Table 1 Initial sample percentages per categoryComponentmaterial:carbon steels ferritic alloys(note 1) austeniticalloysnon-ferrousalloysSample (%) per category (section 4.2.1)Category(section 4.2.1)A B A B A B A B Visualinspection(notes 2 and 3)100 100 100 100 100 100 100 100Forging(notes 2, 6, 7 and 8)UT(note12)0 1000 1000 1000 100 MT10 10 10 10 0 0 0 0 PT 0 0 0 0 10 10 10 10Casting(notes 2,6, 7 and 8)RT 0 10 0 10 0 10 0 10MT10 10 10 10 0 0 0 0PT 0 0 0 0 10 10 10 10Butt welds (notes 5, 6, 8, 11)RT(note 9)100 100 100 100 100 100 100 100MT(note13)10 10 100 1000 0 0 0PT(note13)0 0 0 0 10 10 100100Butt weld valveends of casting(notes 8, 9)RT 100 100 100 100 100 100 100 100Butt weld valve ends of forging (notes 6, 8 )MT 10 10 100 100 0 0 0 0PT 0 0 0 0 10 10 100 100Butt weld valveends of “fabricated” valves(notes 5, 6, 8, 11)RT (note 9)100 100 100 100 100 100 100 100MT (note 13)1010 100 100 0 0 0 0PT(note 13)0 0 0 0 10 10 100 100 Weld overlays(note 3)PT 10 10 10 10 10 10 10 10Hardness test(note 4)10 10 10 10 10 10 10 10 Positive Material Identification (note 10)PMI ApplicableNOTES:1. Including duplex stainless steel and martensitic stainless steel.2. Body, bonnet, cover, body adapter and screwed ball valves inserts.3. Closure members such as gate/wedge, disc, ball, plug, seat rings and seat pocket / stem seal area.4. If required by the applicable standard (e.g. ASTM, NACE MR 0175).5. UT in lieu of RT may be applied if the configuration precludes RT. The UT acceptance criteria shall comply with ASME B16.34 Annex E.6. PT shall be applied if MT is not feasible or when the work efficiency and detection rate of defects is better.7. PT may be applied instead of MT for: - seat rings;- duplex stainless steel materials; - butt-welding ends.8. RT = radiographic examination; MT = magnetic particle examination PT = liquid penetrant examination; UT =ultrasonic examination.9. For all butt welds in cast and fabricated valve bodies including butt weld end preparations, with exception of those made by friction welds. For welded bonnet gate and globe check valves, DN 50 and smaller (designed toAPI 600, API 602, ISO15761) RT is 1% of the lot with a minimum of 1 valve.10. For CS valves as per manufacturer’s standard practice for materials having a P-number of 3 or more (ref. ASME section IX), i.e. alloy steel valves: PMI = 100% for forged & cast pressure retaining components, weld constructions and welding ends (if applicable).PMI = 10% for closure members in valves in nominal sizes DN 40 and smaller.11. For valves with welded on flanged ends and /or welded on bonnets (flanges).12. Only applicable in case of:- valve body and bonnet wall thickness over 100 mm, - end flange thickness over 100 mm, - adaptor flange thickness over 100 mm, - cover flange thickness over 100 mm.13. Weld surface after welding and weld bevel preparation prior to welding.4.3 NDE METHODS AND ACCEPTANCE CRITERIA4.3.1 Visual examination of castings shall be in accordance with MSS SP-55. Visual surfaceexamination of forging shall be in accordance with ASME B16.34 section 8.3.2.2.4.3.2 RT shall comply with ASME B16.34 section 8.3.1.1 (casting) and 8.3.2.1 (forging).UT shall comply with ASME B16.34 section 8.3.1.3 (casting) and 8.3.2.1 (forging).MT shall comply with ASME B16.34 section 8.3.1.2 (casting), 8.3.2.2 (forging) andAnnex C andPT shall comply with ASME B16.34 section 8.3.1.2 (casting), 8.3.2.2 (forging) andAnnex D.4.3.3 Exterior and accessible interior surfaces shall be examined (MP and PT) in the finalmachined condition.4.4 REPAIRDefect removal and repair shall be in accordance with ASME B16.34 section 8.All repairs to duplex stainless steel castings (UNS 31803) require liquid penetrant testingafter excavation of the defect and on completion of repair welding.5. CERTIFICATION AND TRACEABILITY5.1 GENERAL5.1.1 Documentary evidence shall be included in the technical dossier. The manufacturershall store this dossier for at least 10 years. The applicable type of inspectiondocuments shall be as specified in the purchase order.5.1.2 All certificates shall be originals or certified copies.5.1.3 The certificates shall be in the English language or in other languages if they areaccompanied by an endorsed and dated English translation of the contents.5.1.4 Certificates for components shall include certification of the base materials if physicaland mechanical properties of the components differ from those of the base materials. 5.1.5 In case a component is supplied by a processor, or an intermediary, and the componentmaterial deviates from base material, the certificate shall consist of two documentscovering both parts of the manufacturing process, and shall comply with ISO 10474. 5.1.6 The level of certification for both the base materials and the components shall be equal.5.1.7 The manufacturer shall implement a materials tracking system to ensure the correctmaterials are used. The manufacturer shall implement a materials traceability system toensure that materials requiring type 3.1.B certificates are fully traceable to theircertificates.DOCUMENTS5.2 INSPECTION5.2.1 The manufacturer shall be able provide:- inspection certificates in accordance with ISO 10474 type 3.1.B orEN 10204, type 3.1.B ,- test reports in accordance with ISO 10474 type 2.2 or EN 10204, type 2.2 or- certificate of compliance to ISO 10474 type 2.1, as defined in table 2.Table 2 Inspection certificates and test reportsComponent EN 10204 or ISO10474 certificate ortest reportMain pressure bearing parts in PED category I: e.g. body, bonnet, body (screwed) insert, cover, adapter and pressure retaining plugs / bleed connections (flanges)2.2 (note 4)Main pressure bearing parts in PED categories II, III & IV: e.g. body, bonnet, body (screwed) insert, cover, trunnion (in case it is part of the body) adapter and pressure retaining plugs / bleed connections (flanges)3.1.B (notes 2 and 4)Pressure controlling parts: e.g. closure members (gate/wedge, disc, ball, plug and seat rings,2.2 (see note 1)Stem and trunnion 2.2(see note 1)Non pressure bearing parts and sealing components (gaskets,packing, “O”- rings)2.1Hingepin 2.2 Bellows,springs 2.2 Stuffing box follower and gland flange 2.2Bolting (i.e. studs, bolts, screws, nuts). 2.2(notes 1 and 3) Examination (NDE), pressure testing and fugitive emission testing 3.1.B Finished valve in compliance with the specifications 3.1.BNOTES:1. For end users in European member states and countries in the European Free TradeAssociation (EFTA) traceability is sufficiently covered by the PED through Annex I, section3.1.5, Guideline 7/5, note 6.3.For other end users batch traceability is accepted provided the manufacturers documentedbatch traceability procedures guarantee that certification of parts without identification marks are fully traceable to a specific heat or heat treatment lot.2. Ref.: PED guidelines 7/5 and 7/16. Provided the manufacturer has an ISO 9000 series qualitymanagement system certified by a competent notified body and having undergone a specific assesment for materials.3. Ref.: PED guideline 7/8. Bolting is not considered to be main pressure bearing parts unless itsfailure would result in a sudden discharge of pressure. When bolting is used as main pressure bearing parts they shall be certified similar.4. Ref. PED guideline 7/6. Main pressure bearing parts are parts that constitute the pressureenvelope and are essential for the integrity of the equipment.5. Contents of documents:compliance shall state:ofCertificate2.1The manufacturer certifies that the products supplied comply with therequirements of the purchase order, without mention of any test results.The certificate of compliance is a document drawn up on the basis of non-specific inspection and testing.2.2 Test reports shall state:-test results, based on non-specific inspection and testing, specified in thepurchase order;-Principal’s purchase order number;-applicable material standards;-corresponding materials/items including relevant identification markings;-compliance with the specified requirements.3.1.B inspection certificates shall include:-test results, based on specific inspection and testing, specified in the purchaseorder,-manufacturer’s order number;-certificate identification number and date of issue;-a fully detailed material specification;-charge, batch or heat numbers;-both specified and actual mechanical properties and chemical compositions;-N.D.E. methods and results (when applicable);-Positive Material Identification (PMI) test results for materials having a P-number of 3 or more, as defined in ASME section IX;-results of hardness tests (when applicable);-results of impact tests (when applicable);-reference to heat treatment procedure, furnace charge number and heattreatment records (when applicable).6. DOCUMENTATION6.1 The valve manufacturer shall be able to provide documentation, which shall be availableprior to shipment. Computerised data or photo-copies of originals (verified and signed bythe QA/QC-department) may be provided instead of originals.The documentation shall include the following:-purchase order and identification of the valves by serial number or manufacturer's code.-materials test reports and inspection certificates as specified.-NDE reports, including sketches, if necessary, showing the locations of examination.Radiographs shall be retained by the manufacturer for at least five years.-listing of applicable and authorised concessions, waivers and/or material substitutions.-manufacturer's statement of compliance signed by an authorised representative.-all other requirements when valves are supplied with CE mark.-listing of applicable manuals (e.g. assembly/maintenance manuals).7. WITNESSING BY THE PRINCIPAL7.1 The principal shall specify if, and to what extent, he (or his representative) will witnessthe manufacturer's inspections and tests and/or will perform a document review beforeshipment.。
