1、THE ENGINEERING EQUIPMENT AND MATERIALS USERS ASSOCIATION SPECIFICATION FOR INTEGRAL BLOCK AND BLEED VALVE MANIFOLDS FOR DIRECT CONNECTION TO PIPEWORK (2nd Edition) PUBLICATION No 182 : 2004 CORRIGEN DA, JUNE 2004 The corrections/omissions set out below are issued under the authority of the EEMUA Va
2、lves Technical Committee which has responsibility for the maintenance of this publication. 1: 95.2.1 In the second line, amend the date of ASME B16.34 to 1996. 2: 95.4.4 In the first line, after forging insert: or casting,. 3: Section 11, S2 Surface Examination At the end of the subsection insert ad
3、ditional sentence: The acceptance standard for all items less than DN 50 shall be no recordable defects . EEMUA Jun. 2004 PUB 182 CORR THE ENGINEERING EQUIPMENT AND MATERIALS USERS ASSOCIATION SPECIFICATION FOR INTEGRAL BLOCK AND BLEED VALVE MANIFOLDS FOR DIRECT CONNECTION TO PIPEWORK (INCORPORATING
4、 INFORMATION SHEET NO 20: APPLICATION GUIDELINES) (2nd EDITION) PUBLICATION No 182 : 2004 Copyright O 2004 The Engineering Equipment and Materials Users Association ISBN O 85931 125 2 3rd Floor, 20 Long Lane LONDON ECIA 9HL Telephone: 020 7796 1293 Fax: 02077961294 e-mail: website: w.eemua.co. u k s
5、aieseem u a. Co. u k . . . . . . , . ,.,.:.:;:?$s . . . . . $y .A 30 J minimum. 6.10 The seals and gland packings of high temperature (as defined in 5.1.2 (b) manifolds shall be of graphite incorporating a passivating corrosion inhibitor. 6.1 1 Where the seat of metal seated valves is formed from an
6、d integral with the material of the body, the disc or gate shall be harder than the seat. 6.12 Where specified on the data sheet or where dirty or abrasive service is specified, manifolds whose outlets are connected to process pipework shall be provided with main isolating valves having gates, balls
7、, plugs and seats hard-faced with tungsten carbide, Stellite etc. 7 7.1 7.2 7.3 8 8.1 FIRE SAFETY Manifolds incorporating thermoplastic or elastomeric seats or seals shall be covered by fire type-test certification in accordance with IS0 10497, BS 6755 Pt 2,* API Spec. 6FA, API Std 607 or an alterna
8、tive standard acceptable to the purchaser. The complete manifold shall be fire tested. * At the time of writing, IS0 10497 was undergoing revision for reissue as EN IS0 10497. Once the BS EN IS0 is published, BS 6755 Pt 2 will be withdrawn. A test on one valve within a fully assembled manifold quali
9、fies other valves of a similar design subject to the restrictions on size, pressure rating and materials imposed by the relevant fire type-test standard. Manifolds incorporating metal-to-metal sealing and graphite seals may be acceptable without fire test certification by agreement with the purchase
10、r. TESTING The fully assembled manifold shall be hydrostatically tested in accordance with IS0 5208 subject to the following amendments: The test medium shall be fresh water containing, where appropriate, a water-soluble rust inhibitor and wetting agent. In the case of stainless steel manifolds, the
11、 chloride content shall be 20 ppm max. and the pH between 6 and 8.5. Vent connections and threaded outlet connections shall be plugged during the test. 0 Test duration shall be a minimum of 2 min. There shall be no detectable leakage from gland packings or body joints during the test. 9 Manifold bod
12、ies shall be free from external constraints applied in the direction of the pipe axis during the hydrostatic shell test. 8.2 Following hydrostatic testing and with the manifold at its rated pressure, each valve unit shall be operated (opened and closed) three times by hand to demonstrate easy and co
13、nsistent operation. Each valve unit shall then be seat leak tested in accordance with IS0 5208 subject to the following amendments: The test medium shall be: (1) for manifolds incorporating ball or slab gate valves, air or nitrogen at 6 f 1 bar; (2) for all other manifolds and valve types, liquid at
14、 1 .I x rated pressure. Test liquid shall be as in 8.1 above. 0 Test duration shall be a minimum of 1 min. 0 Stabilisation time shall be a maximum of 1 min. Allowable leak rates: (1) soft-seated valves, plug valves and all needle valves-Rate A (2) metal-seated ball and gate valves-Rate C. Each valve
15、 seat shall be tested individually. Testing shall be conducted in a direction from inlet to outlet only, unless otherwise specified by the purchaser, or where manifolds are intended to be fully bi-directional. 8.3 Test equipment shall have been calibrated in accordance with a recognised standard as
16、required by the manufacturers independently assessed and approved quality system, with the results recorded. The accuracy of pressure gauges used in testing shall be in accordance with EN 837-1 Table 1 1, class 1.6 or better. The gauges shall display the test pressure between 25% and 75% of full gau
17、ge range, and have a minimum face diameter of 150 mm. 9 MARKING 9.1 The manifold blocks shall be marked (by vibro-etching or low stress stamping) with the information listed below. Alternatively this information may be chemically etched, vibro- etched or stamped on a stainless steel nameplate attach
18、ed by screws or driven pins. Manufacturers name or trademark manufacturers figure or type number material specification of body and connections (eg Al 05) rating based on inlet flange (eg CI. 900) minimum and maximum working temperatures, from 5.1.2, in OC (e.9. 2Cb120 C) unique serial number IS0 15
19、156 or NACE MR0103 as appropriate min. flow passage bore (mm) with letter S if straight through port (e.9. IO S). For items being put into service in the EEA, marking shall include the CE mark, PED conformity assessment category and module, and, where appropriate, notified body ID. 9.2 Connections s
20、hall be marked as follows: nominal size of inlet flange size, thread type etc. of outlet connection size, thread type etc. of vent connection. 10 10 DOCUMENTATION 10.1 Purchasers Data Sheet As part of the order, the purchaser will provide the manufacturer with a data sheet specifying the requirement
21、s. A model data sheet is given in Appendix C. 10.2 Documentation to be Supplied and/or Retained by the Manufacturer 10.2.1 Material and Test Certification 10.2.1 .I All manifolds shall be certified as complying with this Specification, the requirements of the order, and, for items put into service i
22、n the EEA, the requirements of the PED. 10.2.1.2 Material of the manifold block, valve bonnets and other pressure retaining parts shall be certified in accordance with EN 10204 and provided with a Type 3.1 B certificate. 10.2.1.3 Material of other wetted parts and any bolting shall be provided with
23、a Type 2.2 certificate. 10.2.1.4 All manifolds shall have a certificate confirming satisfactory completion of hydrostatic and seat leak tests. 10.2.1.5 All mill certificates shall be originals or authenticated copies unless otherwise agreed with purchaser. 10.2.2 Traceability Traceability of the man
24、ifold block, valve bonnets and other pressure retaining parts (with the exception of bolting) shall be maintained such that cast / heat numbers can be accessed from the serial number. 10.2.3 Other Documentation 10.2.3.1 Copies of the certificate of conformity and test certificate shall be supplied w
25、ith the manifold unless otherwise stated in the order. 10.2.3.2 All other documentation shall be retained by the manufacturer for a minimum period of five years and shall be available for viewing by the purchaser or inspection agency on request. 10.2.3.3 A design dossier consisting of calculations a
26、nd drawings which demonstrate compliance with Section 5 of this Specification shall be compiled by the manufacturer and retained for a minimum period of five years. This shall be available for viewing by the purchaser or inspection agency on request. Nofe: It is not intended that a unique dossier co
27、ntaining all relevant calculations etc. should be kept for each manifold produced. It is sufficient that the design of the main features (bonnet assembly, bonnet joint, block with standard drilling etc.) be documented for the appropriate materials and standard design conditions, and that the documen
28、tation for a particular assembly (e.g. the general arrangement drawing) refer to this. 11 SUPPLEMENTARY REQUIREMENTS Applicability.- These supplementary requirements need only be met when specifically requested by the purchaser or as otherwise required by this Specification. SI Marking 11 In additio
29、n to the requirements of Section 9 above, the manifold block shall be marked with the purchase order number and the purchasers tag or specification number. Where space is limited, this information may be provided on a stainless steel tag securely wired or riveted to the manifold. S2 Surface Examinat
30、ion The accessible external and internal surfaces of the manifold block, valve bonnets and other pressure retaining parts shall undergo surface examination in accordance with ASME B16.34 Annex C or D. Magnetic particle examination shall be used for ferromagnetic materials except where this is imprac
31、tical. The acceptance standard for all items greater than or equal to DN 50 (for both linear and rounded indications) shall be that specified for rounded indications in forgings in ASME B16.34 Annex C or D. s3 S3.1 S3.2 s3.3 s3.4 s4 Vol u metric Exam i nation Pressure retaining parts shall be examin
32、ed as follows: Castings Examination by radiography. Procedure and acceptance standards in accordance with ASME B16.34 (1996) Annex B. Forgings Ultrasonic examination. Procedure in accordance with ASME V article 5. Acceptance standard in accordance with ASME VIII Div.1 UF55. Weldments All full penetr
33、ation welds shall be subjected to 100% volumetric exam i nat ion by radiographic or ultrasonic techniques. Ultrasonics.- Procedure in accordance with ASME V article 5; acceptance standard in accordance with ASME VIII Appendix 12. Radiography.- Procedure in accordance with ASME V article 2; acceptanc
34、e standard in accordance with ASME VIII UW51. Coverage Coverage for manifolds smaller than DN 50 shall be 100%. Coverage for manifolds equal to or greater than DN 50 shall be of the critical sections unless otherwise specified. Gas Testing Following the hydrostatic shell and seat leak tests required
35、 by this Specification, the manifold shall be shell and seat leak tested at a pressure of 6 bar using clean, oil-free air or nitrogen. Test durations shall be as for hydrostatic testing, and leakage rates in accordance with subsection 8.2. S5 Helium Leak Testing Following the hydrostatic and gas tes
36、ting required by this Specification or called up as a supplementary requirement, a minimum of two manifolds or 10% (whichever is the greater) of each size or pressure rating from each manufacturing batch shall be helium leak tested as follows: The manifolds shall be selected at random from the batch
37、, and in the event of failure to achieve the required degree of tightness, all valves from the batch shall be tested. Testing shall be in accordance with a written procedure which shall be subject to the purchasers approval. Test valves shall be unpainted, and the outside surface shall be cleaned to
38、 remove all dirt, grease and potentially volatile material. Inside and outside surfaces shall be thoroughly dried using clean, warm air. 12 S6 S6.1 S6.2 S6.3 S6.4 S6.5 S6.6 S6.7 s7 S7.1 S7.2 Prior to testing, each valve shall be operated (opened and closed) five times, left for a minimum period of 1
39、 hour, then operated (opened and closed) a further three times. Retightening of glands is permitted, if necessary to prevent leakage, provided operability of the valves is not compromised. 0 With the valves in the half open position and the connections blanked, the manifold shall be enclosed in a se
40、aled bag connected to a mass spectrometer and tested using nitrogen mixed with 1% (by weight) of helium at a pressure of 7 bar. Total leakage shall not exceed 0.0016 ml/s. Requirements for Welded Construction Carbon content = 0.25% max. 0 Carbon equivalent value = C+Mn/G+(Cr+Mo+V)/5+(Cu+Ni)/l 5 = 0.
41、45% max. Carbon steels shall meet the following requirements: Austenitic stainless steels shall have a maximum carbon content of 0.03%. Where duplex stainless steel materials are to be welded, the procedure qualification shall include a metallographic examination in accordance with ASTM E 562 to dem
42、onstrate that the ferrite content is between 35% and 65%. The microstructure shall exhibit no grain boundary carbides and shall be free of sigma, chi and laves phases. All welding and weld deposited hard facing shall be conducted in accordance with written procedures. Procedures and welders shall be
43、 qualified in accordance with ASME IX, or IS0 9606-1 and IS0 9956. Weld procedure qualification shall include impact testing of the weld metal and HAZ in accordance with ASME B31.3 where this is a requirement of the parent metal or where the minimum design temperature is less than -29C. Manifolds in
44、tended for service within the EEA shall meet the essential safety requirements of the PED. Sets of three specimens shall be cut transverse to the weld. Minimum average impact energy values shall be not less than those required for the parent metal. Material impact temperatures may be derived from co
45、nsideration of the design reference temperature according to Figs D.l and D.2, as appropriate, of Annex D to (BSI) PD 5500 (2003). Welds shall be post-weld heat treated where necessary to meet the requirements of IS0 15156 or NACE MR0103, as appropriate, and of the material specification. The weld p
46、rocedure qualification shall include hardness testing. Where fillet welds are qualified by butt welds, the hardness check shall be conducted on a sample of a fillet weld. The accessible surfaces of welds shall be liquid penetrant tested in accordance with ASME V Art. 6 and ASTM E165 to the acceptanc
47、e criteria of ASME VIII Appendix 8. Requirements for Subsea Application General Manifolds intended for subsea application shall meet the additional requirements of S7.2 to S7.4. Manifolds equal to or greater than DN 50 (NPS 2) of Class 150 to Class 2500 rating shall, in addition, meet all the requir
48、ements of EN IS0 14723 QL1 . Where requirements conflict, the most onerous requirement shall apply. Design Body joints and stem sealing arrangements shall incorporate seals designed to exclude seawater at the hydrostatic pressure to which they are to be subjected. The use of gland packings which may
49、 require periodic adjustment is prohibited. Maximum lever and handwheel operating forces shall be restricted to half the value permitted by clause 5.4.17 of this Specification. The design of levers and handwheels shall take into account the restrictions associated with diver operation. 13 ROV interfaces shall be in accordance with one of the standard arrangements specified in IS0 13628-4 or as otherwise specified by the purchaser. The cavity relief requirement of clause 5.4.7 of this Specification need not be met. In the case of welded construction, Supple
