Disouq Field Development Project Supplementary purchasing requirements for valves
Changes List Rev.
Date prepared (DD.MM.YYYY)
Description
A.Y.
First Issue for Client Review
1
14.03.2013
A.Y.
Approved for construction
2
25.08.2013
A.Y.
Approval for construction
0
28.11.2012
Prepared by
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Disouq Field Development Project Supplementary purchasing requirements for valves
CONTENTS
INTRODUCTION............................................................................................................................................. 1
GENERAL ................................................................................................................................................
1.1 1.2 1.3 2
SCOPE .................................................... ....................................................... ........................................... 6 SUBSTITUTIONS ................................................................................................................................... 6 CODES AND STANDARDS ...................................................... ......................................................... .... 6
GENERAL ............................................................................................................................................... 7 VALVE CATEGORIES ..................................................... ........................................................ .............. 7 NON-STANDARD VALVES ..................................................... ......................................................... .... 7 MATERIAL SUBSTITUTIONS ................................................. ....................................................... ...... 7 FACE-TO-FACE ...................................................... ........................................................ ........................ 8 END CONNECTIONS ....................................................... ........................................................ .............. 8 RAISED FACE FINISH ........................................................................................................................... 8 BACK SEATING ..................................................................................................................................... 8 STEM PACKING ..................................................... ........................................................ ........................ 8 TRIM MATERIALS ................................................................................................................................ 8 BODY-BONNET JOINT ......................................................................................................................... 9 BONNET AND GLAND BOLTING........................................................................................................ 9 VALVE OPERATORS............................................................................................................................. 9 DRAIN TAPS ................................................... ....................................................... ................................. 9 END PROTECTION ................................................................................................................................ 9 VALVE CODING .................................................................................................................................... 9 FLANGED OR BUTTWELD SERIES STEEL GATE VALVES .......................................................... 10 FLANGED OR BUTTWELD SERIES STEEL GLOBE VALVES ..................................................... .. 10 FLANGED OR BUTTWELD SERIES CHECK VALVES .................................................................... 10 FERRITIC ALLOY STEEL VALVES .................................................. ................................................. 10 SMALL STEEL AND FERRITIC ALLOY STEEL VALVES ................................................... ............ 10 BRONZE/BRASS VALVES ....................................................... ......................................................... .. 10 VALVES IN SOUR SERVICE .................................................... ......................................................... .. 10 PLUG VALVES ..................................................................................................................................... 11 BALL VALVES ..................................................................................................................................... 11 BUTTERFLY VALVES......................................................................................................................... 11 CAST IRON VALVES ....................................................... ........................................................ ............ 11 COPPER ALLOYS ................................................................................................................................ 11 WELDING PROCEDURES ........................................................ ......................................................... .. 11
INSPECTION AND TESTING .............................................................................................................. 11
3.1 3.2 3.3 3.4 3.5 4
6
VALVE REQUIREMENTS ..................................................................................................................... 7
2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18 2.19 2.20 2.21 2.22 2.23 2.24 2.25 2.26 2.27 2.28 2.29 3
5
VISUAL INSPECTION ......................................................................................................................... 11 NON-DESTRUCTIVE TESTS .............................................................................................................. 12 PRESSURE TESTING ....................................................... ........................................................ ............ 12 IMPACT TESTING .................................................. ........................................................ ...................... 12 NUMBER OF VALVES TO BE TESTED ................................................................................. ............ 13
MARKING .............................................................................................................................................
4.1
VALVE MARKING ................................................. ........................................................ ...................... 13 Page: 3 of 14
13
Disouq Field Development Project Supplementary purchasing requirements for valves 5
ACCESSORIES AND SPARE PARTS ..................................................................................................
5.1 5.2 6
14
ACCESSORIES AND SPARE PARTS ........................................................... ....................................... 14 LOCKING DEVICE ................................................. ........................................................ ...................... 14
PAINTING ..............................................................................................................................................
6.1 6.2
ABOVE GRADE VALVES ................................................................................................................... 14 BURIED VALVES ................................................... ........................................................ ...................... 14
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Disouq Field Development Project Supplementary purchasing requirements for valves INTRODUCTION
RWE Dea Egypt has discovered seven natural gas reserves in the Disouq Concession within the onshore Nile Delta, starting in 2008, as shown on the concession map below. Further exploration in the concession is ongoing. RWE Dea Egypt is the operator of the Concession with EGAS as a partner.
The selected development comprises a central gas treatment site near NSG-1x, where the gas is collected, treated by means of Low Temperature Separation utilizing the Joule Thomson effect to achieve gas quality, and compressed for export. Treated gas is transferred via a 16” pipeli ne directly into the GASCO NTS pipeline. The well fluids are gathered and fed to a common inlet separator at the central plant. All gases and liquids will be separated and processed on the central treatment site into sales gas, stabilized condensate, and free production water. Treatment of gas is carried out in two trains, while treatment of condensate is in a single train. Three trains of sales gas compression are installed. Fuel gas for the gas engine drives is taken from the suction of the sales gas compressors.
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Disouq Field Development Project Supplementary purchasing requirements for valves 1
2
GENERAL 1.1
SCOPE This specification covers the general requirements for valves. It is the intent of this specification to supplement the long descriptions in the material requisitions. These requirements form part of the inquiry and purchase order.
1.2
SUBSTITUTIONS Items specified or referenced by manufacturer and figure number are notintended to exclude equal items offered by other manufacturers. Products of reputable manufacturers and of comparable type, quality and characteristics maybe submitted for RWE's review. Deviations from the purchase descriptions in the requisitions and/or this specification should be clearly highlighted in the bidder's quotation.
1.3
CODES AND STANDARDS All standards, codes and specifications referred to herein form a part of the requirements of this specification. Piping materials std. included in this specification shall be in accordance with the referenced standards shown in Appendix E in ASME B31.3, 2004 and Appendix F in ASME B31.1, 1995.
CODE
EDITION
ASME B16.5 ASME B31.3
2003 2008
ASME B16.10
2004
ASME B1.20.1
2001
ASME B16.11
2009
ASME B16.25
2007
ASTM A53
2004
API 5L
2007
ASME B16.9
2003
ASME B.16.47
2002
ASME B46.1
2006
MSS-SP-43
2008
NACE MR-01-75
2004
MSS-SP-25
2008
ISO9001 ISO14001 OHSAS18001
2008 2009 2007
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Disouq Field Development Project Supplementary purchasing requirements for valves
2
VALVE REQUIREMENTS
2.1
GENERAL The following valve requirements are intended to supplement the basic valve purchase description. Manufacturer's names and model numbers are shown in the purchase descriptions to indicate the desired requirement of valves only. Equals in design, construction, material, and rating may be offered unless otherwise specified.
Requirements of this section apply to valve categories indicated in 2.2.
2.2
VALVE CATEGORIES The valve categories are as follows:- Gate valve - Globe valve - Check valve - Alloy valves - Small steel and ferritic alloy steel valves
-
Brass valves Corrosion-resistant valves Plug valves Ball valves Butterfly valves
2.3
NON-STANDARD VALVES Certain type valves do not conform entirely to ASME pressure and temperature ratings or the standards mentioned in this specification. In such cases, valves that differ somewhat in pressure rating or temperature limits from those of the manufacturer and model number listed in the material requisitions may be offered. Any exceptions to the description in the material requisition form, however, must be clearly noted in the quotation.
2.4
MATERIAL SUBSTITUTIONS Alternative valve designs suitable for the service in the requisition forms may be offered separately. Valve bodies of 9-chrome may be offered when the specified 5 chrome valve bodies are not available. Where Type 304 stainless steel is specified, Type 31 6 stainless steel may be offered. Substitution of austenitic stainless steel valves for ferritic alloy valves must be approved by RWE before the order is placed. Where pressure containing parts have been noted as forged, substitution of castings is not permitted without approval.
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Disouq Field Development Project Supplementary purchasing requirements for valves 2.5
FACE-TO-FACE All flanged and buttwelded end valves shall have face-to-face dimensions in accordance with ASME B16.10, where applicable.
2.6
END CONNECTIONS End connections of flanged steel and cast iron valves shall be in accordance with ASME B16.5 and B16.1 respectively. Flanged valves larger than 24 inches shall have the drilling as stated in the description of the valve.
End flanges shall be integral with body. Flanges applied by full penetration buttwelding are allowed only if specified. End connections of threaded and socketweld valves shall be in accordance with the following: -
Threaded valves Socketweld valves
- Internally tapered threads per ASME B2.1 - Internal sockets per ASME B16.11.
End connections of carbon steel buttweld end valves shall have machined ends in accordance with ASME B16.25, Figures 1, 2 or 3.
2.7
RAISED FACE FINISH The valve flange contact face finish shall be in accordance with the following:
2.7.1 Class 150 flanges shall have a serrated finish (concentric or spiral) with a roughness between 250 and 500 AARH (micro inches) for non-metallic gaskets. 2.7.2 Whenever smooth flanges finish between 125 and 250 AARH is required, it will be specified in RWE's purchase description.
2.8
2.9
BACK SEATING Back seating is required for gate and globe valves to permit repacking under pressure while the valve is in the open position.
STEM PACKING Packing for all valves shall be manufacturer’s standard and subject to RWE approval.
2.10 TRIM MATERIALS Valve trim materials shall be in accordance with RWE's valve description. Hard facing shall be manufacturer's standard. Where 11-13 chrome trim is specified, stellitedseats or stellited seat and disc may be substituted.
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Disouq Field Development Project Supplementary purchasing requirements for valves 2.11 BODY-BONNET JOINT Metallic and non-metallic bonnet gaskets shall have corrosion resistance equal, or greater than that of the body and bonnet materials. When specifically called for, Bonnet gasket material shall be as specified in the RWE’s valve description.
2.12 BONNET AND GLAND BOLTING
Bonnet boltingshall be ASTM A193, Grade B7 for carbon steel and ferritic alloy steel valves. Strain hardened austenitic stainless steel bonnet bolts shall be used for stainless steel and 3 1/2 percent nickel valves. Bonnet bolting for killed carbon steel valves shall be ASTM A 193, Grade B7, quenched and tempered, or strain hardened austenitic stainless steel. Where corrosion resistant bonnet bolting is specified in the valve purchase description, bonnet bolts smaller than 1/2-inch shall be ASTM A193, Grade B6, and bonnet bolts 1/2 inch and larger shall be ASTM A193, Grade B7, hot dip galvanized. Where corrosion resistant gland bolting is spe cified in the valve purchase description, the bolting material for the eyebolts and the lug bolts shall be Type 304 or Type 316 stainless steel or 13 chrome. 2.13 VALVE OPERATORS Where gear operators are specified, valves shall be provided with manufacturer's standard enclosed gear operators.
Gear operators, shall have hot dipped galvanized clamps and austenitic stainless steel bolting. Gear operators shall be identified in the Material Requisition for specific sizes and pressure / temperature rating.
2.14 DRAIN TAPS Any valve specified with drain taps shall be furnished drilled and tapped at locations indicated in the RWE valve description.Threads shall be tapered pipe threads in accordance w ith ASME B2.1. Drain taps shall be fitted with forged plugs in accordance with ASME B16.11 of the same basic body material as the valve body.
All gate valves shall have inspection and testing in accordance with API-598, by the manufacturer.
2.15 END PROTECTION Gate and globe valves shall be shipped in the closed position and plug andball valves shall be shipped in the open position. Butterfly valves shall be shipped with the disc cracke d slightly open but the disc shall not protrude beyond the valvebody. Valves shall be shipped with the stempacking installed.
Faces of flanged valves shallflange be protected over the entire gasket withValves metal,with hardboard, solid plastic, or solid wood protectors securely attached to surface the valve. screwedheavy or socketweld ends shall have the ends protected with metal, wood, or plastic plugs. 2.16 VALVE CODING Valve codes arecomposed of letters and numbers.The valve sizeprefixes the code.
All buttweld valve call-outs must specify the wall thickness at the weld bev el along with the size. For example, a 6-inch schedule 40-bore buttweld valve is called out as 6"x.280.The size and the wall thickness shall prefix the valve code. Page: 9 of 14
Disouq Field Development Project Supplementary purchasing requirements for valves
The valve code identifies the valve from the time it is ordered until it is installed. The valve manufacturer shall attach to each valve a corrosion resistant tag with RWE's valve code number, as a part of valve marking (see para.4.1). The tag shall be placed either under the handwheel nut or a bonnet bolt. 2.17 FLANGED OR BUTTWELD SERIES STEEL GATE VALVES
Gate valves shall conform to all requirements of API-600, ASME B16.34, or other codes called for in the Material Requisition. Where the gate valve specified has asolid wedge, a valve with a flexible wedge may be offered for consideration. 2.18 FLANGED OR BUTTWELD SERIES STEEL GLOBE VALVES Globe valves shall conform to API-600, and ASME B16.34, or other codes called for in the Material Requisition where applicable (handwheel and trim material, bonnet gasket, bonnet bolting, marking, body and bonnet wall thickness, etc).
2.19 FLANGED OR BUTTWELD SERIES CHECK VALVES Check valves shall conform to API-600, and ASME B16.34, or other codes called for in the Material Requisition where applicable (materials, bonnet bolting, marking, body wall thicknesses, etc.). Any deviations from ASME B16.10 face to face dimensions shall be clearly stated in the quotation.
Wafer-type check valves shall conform toAPI-594. 2.20 FERRITIC ALLOY STEEL VALVES Flanged gate, globe, and check valves constructed of Ferritic alloy,P-6 and under, shall meet the above requirements for steel gate, globe, andcheck valves. 2.21 SMALL STEEL AND FERRITIC ALLOY STEEL VALVES These valves shall conform to API-602 or as specifically called for in the Material Requisition.
Where small forged alloy steel valves have been specified in the valve descriptions, the substitution of cast valves is not permitted without approval from RWE.
2.22 BRONZE/BRASS VALVES Manufacturer's standard valves are acceptable unless specific requirements are given in the valve description.
2.23 VALVES IN SOUR SERVICE Where valves are subject to sour service as defined by the code NACE MR-01-75, the materials of construction, heat treatments, welding and hardness shall be in accordance with the requirements of this applicable code.
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Disouq Field Development Project Supplementary purchasing requirements for valves 2.24 PLUG VALVES These valves shall conform to API-599 and API-593 where applicable. All lubricated plug valves shall have giant button head lubricators. Each wrench-operated plug valve shall be furnished with wrench.
2.25 BALL VALVES
These valves shall conform to ASME B16.34 where applicable. Soft seated ball valves ordered with fire-tested design shall include a secondary metal seal as a back-up for theprimary seat. Each wrenchoperated ball valve shall be furnished with a wrench. Metal seated ball valve shall be specified for high temperature services and/or erosive services.
2.26 BUTTERFLY VALVES These valves shall conform to API-609 where applicable. All wrench-operatedbutterfly valves shall have notched throttling plates. Rubber seated butterfly valves shall be used for Fire Fighting service. Metal seated types shall be used for high temperature services with tight shut-off requirements.
2.27 CAST IRON VALVES Cast iron gates, globes andchecks shall generally conform to API-595 and where applicableAWWA C-500.
2.28 COPPER ALLOYS Where valves are specified "no brass, copper, or copper alloys permitted", this shall be understood to mean that no copper alloy material shall be used in the construction of these valves, including internal and external parts.
2.29 WELDING PROCEDURES The supplier shall, furnish welding procedure qualifications for RWE's approval, for valves requiring pressure retaining welds(including seal welds and weld repairs to casting). The procedures and qualification shall include hardness testing in accordance with ASTM-A370 (specifically 16.0 and 17.0) for materials with maximum hardness limitations shown in ASME B31.3, table 331.3.1 as well as all the materials under the regulations of NACE code MR-01-75 (Latest Revision). The hardness testing shall be performed on the weld and the heat affected zone and after any required heat treatment. 3
INSPECTION AND TESTING
3.1
VISUAL INSPECTION Cast steel valve bodies shall be sound and free of visual defects in accordance with MSS-SP-55. Visual inspection shall be witnessed by RWE's inspector.
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Disouq Field Development Project Supplementary purchasing requirements for valves 3.2
NON-DESTRUCTIVE TESTS Radiographic, ultrasonic or magnetic particle examinations of valve bodies shall be executed by the manufacturer only in the following cases:
3.2.1. Casted valves with ASME rating 900 pound and higher: Valves sizes 16-INCH and Smaller, one valve for each size shall be radiographed. All valves sizes 18" and larger shall be radiographed. Radiography shall be in accordance to ASME B16.34.
3.2.2. Valves bodies and bonnets made by weldassembly of segments of castings, forgings, bars, tubular products or plates or combinations. All pressure retaining welds shall be examined in accordance with ASME SEC.VIII-division I for 100% of the valves to assure a weld joint efficiency of 1.0. Certified records of these tests shall be submitted to RWE for review. 3.2.4
3.3
All forged valves with shall undergo a 100% ultrasonic examination in accordance with code ASME B16.34.
PRESSURE TESTING Pressure testing for valves shall generally be conducted in accordance with the codes specified herein and the standards to which they are designed.
3.3.1 All and ductile valves shall basically bepressure pressuretest tested in accordance with API-598 andsteel ASME B16.34.ironManufacturer's standard may be used only after the consent of approval by RWE to the manufacturer's submitted procedures. Valves manufactured to API spec. 6D shall be tested in accordance with this code. 3.3.2 Pressure tests shall be as follows: a. Shell test pressure including body, bonnet and cover plate at not less than 1.5 times the pressure rating at 38 oC rounded off to the next higher one bar increment. b. Seat test pressure at 1.1 times the pressure rating at 38 oC rounded off to the next higher one bar increment. c. Low-pressure seat test at 6.9 bars (air test). d. High-pressure closure at 1.1 timesthe pressure rating at 38oC rounded off to the next higher one bar increment. (See Para. 7.2 of ASME B16.34). 3.3.3 RWE’s inspector shall witness all the pressure tests.
3.4
IMPACT TESTING Requirements for impact testing of materials shall be governed bythe provisions of paragraph 323.2.2 of ASME B31.3. The testing methods and acceptance criteria shall be in accordance with paragraph 323.3 of ASME B31.3.
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Disouq Field Development Project Supplementary purchasing requirements for valves 3.5
NUMBER OF VALVES TO BE TESTED Valves to be tested in the presence of RWE inspector are as follows:
3.5.1 For nominal valves sizes 14 inch and smaller and rating upot 800 pound ASME, the number of valves to be tested = square root of the quantity in the lot. 3.5.2
For nominal valves sizes 16– inch and larger and rating up to 800 pound ASME, all valves shall be tested.
3.5.3
For nominal valves all sizes rating ASME class 900 & above, all valves shall be tested.
3.6 REPAIRS
3.6.1 Repair of shell defects in cast steel valves, as defined in the applicable ASTM, code are permitted only after the consent of approval by RWE on the manufacturer's repair weld procedure, valves shall be retested after repair. 3.6.2 Casting repairs of cast iron and ductile iron valves is not permitted. 3.6.3 Repair of castings mechanical means with metal plugs, or impregnation with metallic or non metallic materials are not permitted.
4
MARKING
4.1
VALVE MARKING All valves shall generally be marked in accordance with MSS-SP-25 and ASME B16.34 as well as the following: 4.1.1 BODY MARKING Manufacturer name or trade name. Material designation. Melt identification. ASME pressure rating Size.
On valves where size of shape limits the body marking, they may be omitted in the opposite direction of the above sequence. 4.1.2 Identification platemarking. -
Manufacturer name or trade mark. Valve trim identification. Valve body identification. ASME pressure rating. Valve size and code (as per parag. 2.16). Limiting maximum temperature (for soft seated valves).
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Disouq Field Development Project Supplementary purchasing requirements for valves
5
ACCESSORIES AND SPARE PARTS
5.1
ACCESSORIES AND SPARE PARTS When specifically mentioned in the Material Requisition accessories and spare parts to be furnished together with the ordered valves shall be suitable for 2 years service. Bidders shall proposehese t items and include them in a separate quotation.
5.2
LOCKING DEVICE When valve locking device is called for, the valve shall be locked in bothhe t closed or open position by means of padlock or pin as standard. Such device with padlock shall be included in the vendor's supply scope. Vendor shall propose his locking system for the valv es for acceptance by RWE.
6
PAINTING
6.1 ABOVE GRADE VALVES All valves installed above grade shall be prepared and painted according to the manufacturer standard, unless otherwise specifically called for in the Material Requisition or as agreed upon between RWE and manufacturer.
6.2
BURIED VALVES shall be protected by two or three layers of epoxy-tar painting reaching a total min. thickness of 400 microns(Unless otherwise specifically called for in the Material Requisition) Before painting, surfaces shall be clean, free of rust or grease and completely dried up. epoxy is environmentally friendly painting type
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