APPROVAL BODY INSTYTUT NAFTY I GAZU PAŃSTWOWY INSTYTUT BADAWCZY OIL AND GAS INSTITUTE - NATIONAL RESEARCH INSTITUTE (INiG-PIB) PL 31-503 Kraków, ul. Lubicz 25 A tel.: +48 12 4210033 fax: +48 12 4210050 TECHNICAL APPROVAL Product name: Applicant: Fabryka Armatur JAFAR S.A. ul. Kadyiego 12 38-200 Jasło (Poland) TA no.: AT/97-04-0047 Edition V/2015 Date of expiry: 25 November 2020 Page: 1 of 14 APPROVED FOR USE BY: Krakow, 26 November 2015 Instytut Nafty i Gazu (Oil and Gas Institute) Państwowy Instytut Badawczy(National Research Institute) Managing Director Oil and Gas Institute - National Research Institute Maria Ciechanowska INiG-PIB Managing Director ACCEPTED FOR USE BY: CEO Edward Gierut Jasło, 30 November 2015 The Technical Approval one-pager sheet is integral to this multi-page Technical Approval no. AT/97-04-0047 edition V/2015.
A. DESCRIPTION 1. SUBJECT OF TECHNICAL APPROVAL 1.1. General technical specification The soft-seal wedge gate valves manufactured by JAFAR are intended to isolate NG (natural gas) flow in NG distribution systems. The following generic types of the wedge gate valves are manufactured: - TYPE 2302 and TYPE 2311, with flanged ends (Img. 1); - TYPE 2316, TYPE 2326 and TYPE 2416 are made with threaded ends. TYPE 2302 and TYPE 2311 with controllable drive actuators are designated TYPE 2931 and TYPE 2932, respectively. TYPE 2302 and TYPE 2311 with closure position indicators are designated TYPE 2531 and TYPE 2532, respectively. TYPE 2311 and TYPE 2302 are operated (opened and closed) manually with a hand wheel the diameter of which is matched to the wedge gate valve size. The NG flow closure is a wedge with 100% elastomer coating, driven by a steel rotating spindle, which is sealed from the wedge gate valve body with a system of o-rings. The wedge gate valve body is coupled to the drive actuator cover with bolts and sealed with a profiled gasket made of NBR. The wedge gate valve is finished with a coat of epoxy resin in yellow, for anti-corrosion protection. The wedge gate valves can optionally be equipped with a closure position indicator. Img. 1. TYPE 2302 and TYPE 2311 wedge gate valves AT/97-04-0047 Edition V/2015 Page: 2
2. INTENDED USE WITH APPLICATION SCOPE AND CONDITIONS TYPE 2302, TYPE 2311, TYPE 2316, TYPE 2326 and TYPE 2416 full-bore soft-seal wedge gate dampers are intended to isolate NG flow (per PN-C 04750:2011) in NG pipelines and at NG metering and pressure reduction stations. The NG system operating temperatures for the listed wedge gate valves are as follows: - TYPE 2302 and TYPE 2311: -30 C to +60 C - TYPE 2316, TYPE 2326 and TYPE 2416: -30 C to +60 C TYPE 2302 and TYPE 2311 wedge gate valves are manufactured in a nominal diameter type series from DN 32 to DN 600 at MOP 16 (maximum operating pressure of 16 bar). TYPE 2316, TYPE 2326 and TYPE 2416 wedge gate valves are manufactured in a nominal diameter type series of DN 25, DN 32, DN 40 and DN 50 at MOP 5 (maximum operating pressure of 5 bar). The wedge gate valves are intended to be operated as cut-off valves, i.e. they may only work either in the fully open or fully closed position. 3. DESIGN REQUIREMENTS 3.1. Design The wedge gate valve bodies are fully cast according to the technical specification file. The wedge gate valve ends meet the applicable standards and regulations. 3.2. Materials The materials are selected pursuant to valid standards and regulations (PN-EN 13774:2013-07 clause 5.2.) and, under normal operating condition, resist mechanical, thermal and chemical deterioration without ageing below a specific durability. The wedge gate valve bodies and closure wedges are made of EN-GJS-400-15 or EN-GJS-350-22-LT ductile cast iron. The wedge seal is made of NBR (nitrile butyl rubber). The closure wedge driving spindle is made of grade X20 Cr13 steel and features an NBR seal. 3.3. Dimensions The main dimensions are as listed in the technical specification file. Flanged ends are manufactured per PN-BN 1092-2:1999. Threaded ends are manufactured per PN-BN 10226-1:2006. 4. FUNCTIONAL REQUIREMENTS 4.1. Operating principle TYPE 2302 and TYPE 2311 wedge gate valves are operated manually with a hand wheel. TYPE 2931 and TYPE 2932 wedge gate valves are operated by multi-turn electric or pneumatic drive actuators (the electric drive actuators are Ex-proof). The closing and opening operation is smooth (stepless), without breaks, jamming or transient resistance. The driving torque required to operate a wedge gate valve and expressed in Newton metres (Nm) is determined per PN-EN 12570:2002. AT/97-04-0047 Edition V/2015 Page: 3
4.2. Strength Each wedge gate valve is hydraulic pressure tested per PN-EN 12266-1:2012 Annex A, clause A.2. 4.3. Seal integrity 4.3.1. External seal integrity Each wedge gate valve is hydraulic or pneumatic pressure tested per PN-EN 12266-1:2012 Annex A, clause A.3. 4.3.2. Internal seal integrity Each wedge gate valve is pneumatic pressure tested per PN-EN 12266-1:2012 Annex A, clause A.4. 4.3.3. Seal integrity (of the body and the packing gland) at lower and higher temperatures The wedge gate valves retain seal integrity of the body and the packing gland from -30 C to +60 C. 4.4. Durability The wedge gate valves remain sealed after the number of full closing and opening cycles listed in Table 1. Table 1 Nominal dimension [mm] Cycles < DN 100 200 DN 100 200 AT/97-04-0047 Edition V/2015 Page: 4
4.5. Labelling The labelling of the wedge gate valves shall specify the following information as a minimum: manufacturer's name or mark; model/type; nominal dimension (DN); maximum operating pressure (MOP); temperature range; body material; TA number; construction approval mark. Example of labelling: JAFAR, TYP 2311, DN 250, MOP 16, -30 C +60 C, EN-GJS-350-22-LT, AT/97-04-0047 A manufacturer's authorised representative with the business registered in Poland provides the National Declaration of Conformity with this Technical Approval. 5. EXAMINATION TESTING 5.1. Initial type examination The initial type examination of the wedge gate valves with flanged ends is done to prove compliance with this Technical Approval: before a new wedge gate valve market launch; before the production of new wedge gate valves or wedge gate valves with design modifications; after implementing a new production method, if it has a potential to affect specific characteristic of the wedge gate valves. 5.2. Sampling The initial type examination is done on samples taken by random from series production, unless the samples are prototypes of a wedge gate valve. At least three (3) wedge gate valves are sampled with three selected nominal dimensions. The examination and test criteria are listed in Table 2. AT/97-04-0047 Edition V/2015 Page: 5
Table 2 Tested characteristic Requirements ref. AT/97-04-0047 Ed. V/2015, Section: Tests ref. AT/97-04-0047 Ed. V/2015, Section: Compliance criteria Design 3.1. 5.3.1.1. Technical specification file compliance Materials 3.2. 5.3.1.2. Material certificates inspection Dimensions 3.3. 5.3.1.3. Dimensional compliance with design drawings Operating principle 4.1. 5.3.2.1. Ease of operation Strength 4.2. 5.3.2.2. Zero deformation External seal integrity 4.3.1. 5.3.2.3. Seal integrity Internal seal integrity 4.3.2. 5.3.2.4. Seal integrity Seal integrity at lower and 4.3.3. 5.3.2.3. 5.3.2.4. Seal integrity higher temperatures Durability 4.4. 5.3.2.5. Seal integrity after cycling Labelling 4.5. 5.3.2.6. Labelling compliance 5.3. Description of examination tests 5.3.1. Design requirements verification 5.3.1.1. Design check The design is verified by comparing the actual wedge gate valve to its technical specification file. 5.3.1.2. Materials verification The materials are verified by inspecting the attestations and quality certificates of the materials which the wedge gate valve has been made of. 5.3.1.3. Dimensional verification The dimensions and tolerances are verified with universal measurement tools and gauges. The verification includes overall dimensions and connection end dimensions of the wedge gate valve as specified on its assembly drawings. 5.3.2. Functional requirements verification 5.3.2.1. Operating verification The operation is verified by opening and closing the gate valve dry (without its operating medium) at least three times at ambient temperature. The driving torque is measured with a torque wrench per the method of PN-EN 13774:2013-07 Annex B, clause A.2.2. 5.3.2.2. Strength verification The strength is verified per PN-EN 12266-1:2012 Annex A, clause A.2, Test P10. 5.3.2.3. External seal integrity verification The external seal integrity is verified per PN-EN 12266-1:2012 Annex A, clause A.3, Test P11. 5.3.2.4. Internal (closure) seal integrity verification The internal (closure) seal integrity is verified per PN-EN 12266-1:2012 Annex A, clause A.4, Test P12. AT/97-04-0047 Edition V/2015 Page: 6
5.3.2.5. Durability check The durability is verified by opening and closing the wedge gate valve in a number of cycles specified in Section 4.4. Once the prescribed number of cycles has been done, the wedge gate valve seal integrity is tested per Section 5.4.2.3 and 5.4.2.4. 5.3.2.6. Labelling verification The labelling is verified by proving that it is legible and complete per Section 4.5. 5.4. Factory production control (FPC) requirements 5.4.1. General The manufacturer establishes, documents and manages an FPC (factory production control) system to assure that the products marketed comply with their declared performance characteristics. The FPC system includes: FPC procedures (a Quality Manual), periodic inspections, and tests; the FPC is performed based on control results from batches, other input materials or components, equipment, the manufacturing process, and the finished products. These records remain legible, easily traceable and retrievable. The FPC system is compliant with PN-EN ISO 9001:2009+AC and meets these requirements. The results of control, tests or evaluations that require corrective action are recorded with evidence of the actions completed. Corrective action is taken when control values or criteria are not met; the actions are recorded and kept on file for a period specified in the FPC procedures. 5.4.2. Product testing under FPC Table 3 lists the in-production and finished product tests for the wedge gate valves. These tests are done for verification purposes and at ambient temperature. AT/97-04-0047 Edition V/2015 Page: 7
Table 3 Tested characteristic Requirements / tests ref. AT/97-04-0047 Testing frequency Ed. V/2015 Dimensions 3.3. / 5.3.1.3. Statistica, per manuf.'s procedure Operating principle 4.1. / 5.3.2.1 100% Strength 4.2 / 5.3.2.2 100% External seal integrity 4.3.1. / 5.3.2.3. 100% Internal seal integrity 4.3.2. / 5.3.2.4. 100% 5.4.3. Non-conforming products The manufacturer has established procedures in writing for handling of products that do not conform to this TA. All emerging non-conformities are recorded and kept on file for a period specified in the established, written FPC procedures. Compliance of the non-conforming product handling procedures with EN ISO 9001:2009+AC clause 8.3 is sufficient to meet the requirements in this Section. 5.4.4. Corrective actions The manufacturer has established written corrective procedures that prompt the action required to remove root causes of non-conforming products to achieve product compliance and/or prevent recurrence of nonconformities. 6. PACKING, STORAGE AND TRANSPORT 6.1. The wedge gate valves are packed as recommended by the manufacturer; the packaging protects the product from internal contamination. 6.2. The wedge gate valves in storage are protected against weather and aggressive chemicals. 6.3. During transport, the wedge gate valves are kept firmly against one another. AT/97-04-0047 Edition V/2015 Page: 8
7. FORMAL AND LEGAL CONDITIONS 7.1. Terms of delivery The Technical Approval is not an authorization for use of the product in construction or marketing in the Republic of Poland. The Technical Approval is only a reference document which establishes a set of requirements for the product it applies to. Pursuant to 4.1. of the Polish Regulation of the Ministry of Infrastructure dated 11/08/2004 and concerning the methods for declaring conformity of construction products and applying the construction approval mark (Journal of Laws 10/09/2004, no. 198, item 2041 as amended), this product has been qualified for conformity assessment system 3 and can be marketed and applied for construction work if a National Declaration of Conformity with this Technical Approval is granted by the manufacturer or their representative with the business registered in Poland. The product shall be supplied with the information established in 12.1 of the Polish Regulation of the Ministry of Infrastructure dated 11/08/2004 (Journal of Laws 10/09/2004, no. 198, item 2041 as amended). The wedge gate valves for NG systems shall be subject to the assessment of conformity with the Technical Approval under conformity assessment system 3; this means that a manufacturer's authorized representative with the business registered in Poland shall declare conformity of the product as proven by: a) an initial type examination completed by an accredited laboratory; b) the Factory Production Control. 7.2. Using this Technical Approval 7.2.1. The product supplier who has been granted this Technical Approval from INiG-PIB shall refer to it by its reference number and date of expiry in all documents related to marketing and application of the product under this Technical Approval. No text or drawing in product catalogues, folders and other materials related to that product must conform with the Technical Approval. 7.2.2. The Technical Approval from INiG-PIB does not replace any permit from construction authorities required to allow construction work with the product. The Technical Approval shall be presented on request of construction authorities, product buyers and all interested parties on an authenticated copy or the original copy issued by INiG-PIB. 7.2.3. The INiG-PIB Technical Approval shall only be presented in full. The product supplier is authorized to use copies of the Technical Approval one-pager sheet for promotional purposes only. However, no copy or reproduction of the Technical Approval one-pager sheet shall substitute the full multi-page Technical Approval. Copying or reproducing the Technical Approval otherwise in part is prohibited by the Polish Act of 23 August 2007 on prevention of unfair market practice (Journal of Laws 20/09/2007, no. 171, item 1206). AT/97-04-0047 Edition V/2015 Page: 9
7.3. Protection of exclusive rights 7.3.1. This Technical Approval does not violate any third-party rights imposed by industrial property protection laws listed in the Notice of the Speaker of the Polish Sejm dated 13 June 2003 and concerning the declaration of a consolidated text of the Industrial Property Law (Journal of Laws 9/07/2003, no. 119, item 1117 as amended). The security of third-party rights is a legal obligation of the manufacturer and distributors who use the technical solution embodied by the product under the INiG-PIB Technical Approval. 7.3.2. INiG-PIB may amend the Technical Approval it has issued with prior notice to the original Applicant, at sole discretion of INiG-PIB, motivated by advancements in the state of the art and/or laws and regulations. The product supplier who has been granted this Technical Approval from INiG-PIB shall refer to it by its reference number and date of expiry in all documents they publish as related to marketing and application of the product under this Technical Approval. AT/97-04-0047 Edition V/2015 Page: 10
8. DATE OF EXPIRY This INiG-PIB Technical Approval no. AT/97-04-0047 Ed. V/2015 shall expire on 25 November 2020. This INiG-PIB Technical Approval can be extended for a period of identical duration as from the original issue to its date of expiry if the original Applicant or their legal successor requests the extension 3 months before the valid date of expiry hereof at the latest. By general principle, the Technical Approval shall expire after 5 years past its original date of issue for the product in current production, with the performance characteristics and technical properties fully confirmed by type examination, and the manufacturing conditions that assure stable levels of applicable requirements. AT/97-04-0047 Edition V/2015 Page: 11
B. ACCEPTANCE Pursuant to the Polish Regulation of the Ministry of Infrastructure dated 8 November 2004 and concerning technical approvals and organized bodies authorized for issue thereof (Journal of Laws 23/11/2004, no. 249, item 2497 as amended), following the Approval Procedure completed by the Oil and Gas Institute - National Research Institute (INiG-PIB) and requested by the Applicant: Fabryka Armatur JAFAR S.A. ul. Kadyiego 12 38-200 Jasło (Poland) the following construction product has been found fit for use in construction: wedge gate valves intended for installation in NG distribution systems, type series: - TYPE 2302 (TYPE 2932, TYPE 2532) and TYPE 2311 (TYPE 2931, TYPE 2531) with flanged ends, nominal diameter range from DN32 to DN600, MOP 16 (16 bar), operating temperature range from -30 C to +60 C; - TYPE 2316, TYPE 2326 and TYPE 2416 with threaded ends, nominal diameter range: DN25, DN32, DN40, and DN50, MOP 5 (5 bar), operating temperature range from -30 C to +60 C. Kraków, 26 November 2015. Chairman of Technical Approval Committee Mgr inż. Krzysztof Dybaś (MSc Eng.) Head of Technical Approval Dept. Mgr inż. Tadeusz Dziedzic (MSc Eng.) Managing Director of Oil and Gas Institute - National Research Institute Maria Ciechanowska Chairman, KAT Head, DW Managing Director, INiG-PIB This Technical Approval is not an authorization for use of the product in Poland. It only forms a substance for such authorization, pursuant to Section 7.1 hereof. *** END *** AT/97-04-0047 Edition V/2015 Page: 12
C. OTHER INFORMATION: 1. Notice of requirements for use in construction TYPE 2311 and TYPE 2302 wedge gate valves shall be used per the manufacturer's recommendations and the requirements established by NG system operators. 2. References: PN-EN 682:2004/A1:2006 PN-EN 1092-2:1999 PN-EN 1555-2:2012 Elastomeric seals. Materials requirements for seals used in pipes and fi ttings carrying gas and hydrocarbon fluids Flanges and their joints. Circular flanges for pipes, valves, fittings and accessories, PN designated. Part 2: Cast iron flanges. Plastics piping systems for the supply of gaseous fuels. Polyethylene (PE). Part 2: Pipes. PN-EN 1555-3+A1:2013-05 Plastics piping systems for the supply of gaseous fuels. Polyethylene (PE). Part 3: Fittings. PN-EN 1092-1+A1:2013-07 Flanges and their joints. Circular flanges for pipes, valves, fittings and accessories, PN designated. Part 1: Steel flanges. PN-EN 1984:2010 PN-EN 12627:2002 PN-EN 1171:2007 Industrial valves. Steel gate valves. Industrial valves. Butt welding ends for steel valves. Industrial valves. Cast iron gate valves. PN-EN 10226-1:2006 Pipe threads where pressure tight joints are made on the threads. Part 1: Taper external threads and parallel internal threads. Dimensions, tolerances and designation. PN-EN 12266-1:2012 PN-EN 12266-2:2012 PN-EN 12570:2002 PN-EN 13774:2013-07 PN-EN ISO 228-1:2005 Industrial valves. Testing of valves. Part 1: Pressure tests, test procedures and acceptance criteria. Mandatory requirements. Industrial valves. Testing of valves. Part 2: Pressure testing, test procedures and acceptance criteria. Supplementary requirements. Industrial valves. Method for sizing the operating element. Valves for gas distribution systems with maximum operating pressure less than or equal to 16 bar. Performance requirements. Pipe threads where pressure-tight joints are not made on the threads. Part 1: Dimensions, tolerances and designation. PN-EN ISO/IEC 17050-1:2010 Conformity assessment. Supplier's declaration of conformity. Part 1: General requirements. PN-ISO 724:1995 PN-N-03010:1983 ISO general purpose metric screw threads. Nominal dimensions. Statistical quality control. Sampling of product units for testing. AT/97-04-0047 Edition V/2015 Page: 13
Polish Regulation of the Ministry of Economy dated 26 April 2013 and concerning the technical requirements for natural gas systems and locations thereof (Journal of Laws 2013 no. 0 item 640). Polish Construction Products Act of 16 April 2004 (Journal of Laws 2004 no. 92 item 881). Notice of the Speaker of the Polish Sejm dated 14 May 2014 and concerning the declaration of a consolidated text of the Polish Construction Products Act (Journal of Laws 2 July 2014, item 883). Polish Regulation of the Ministry of Infrastructure dated 8 November 2004 and concerning technical approvals and organized bodies authorized for issue thereof (Journal of Laws 23/11/2004, no. 249 item 2497 with amendments published in Journal of Laws 2010 no. 34 item 183 and Journal of Laws 2013 no. 0 item 46). Polish Regulation of the Ministry of Infrastructure dated 11/08/2004 and concerning the methods for declaring conformity of construction products and applying the construction approval mark (Journal of Laws 10.09.2004, no. 198 item 2041 with amendment published in Journal of Laws 2006 no. 245 item 178). TA Appendix no. 19/96, Ed. VI.2009: Guidelines for Technical Approval product. Requirements and testing. "" with Annex 1 of 26/04/2012 and Annex 2 of 27/11/2013. Laboratory Test Report no. 11/A/GP-1/15 for "Type 2311 and 2302 soft-seal wedge gate valves with flanged ends for NG systems", developed by INiG-PIB Laboratory GP-1, dated 15/10/2015. 3. Manufacturer: Fabryka Armatur JAFAR S.A. ul. Kadyiego 12 38-200 Jasło (Poland) 4. Manufacturing plant: Fabryka Armatur JAFAR S.A. ul. Kadyiego 12 38-200 Jasło (Poland) Prepared by: inż. Andrzej Kobylarz (Eng.) AT/97-04-0047 Edition V/2015 Page: 14