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HP Duplex Ball Valves 01-P-1-008 Rev 07 - Item1&2
HP Duplex Ball Valves 01-P-1-008 Rev 07 - Item1&2
HP Duplex Ball Valves 01-P-1-008 Rev 07 - Item1&2
1 INTRODUCTION ..................................................................................................................
1.1 General .................................................................................................................................. 4
1.2 Scope of Document ................................................................................................................ 4
1.3 Definitions ............................................................................................................................... 4
1.4 Abbreviations .......................................................................................................................... 4
1.5 Compliance ............................................................................................................................ 5
1.6 Quality Conformance .............................................................................................................. 5
1.7 Safety ..................................................................................................................................... 5
2 SPECIFICATIONS, CODES AND STANDARDS
2.1 General .................................................................................................................................. 6
2.2 Standards and Codes ............................................................................................................. 6
3 DESIGN AND OPERATING DATA ................................................................................................... 7
3.1 COMPANY Expediting and Inspection ...................................................................... 7
4 BALL VALVE DESIGN
4.1 General .................................................................................................................................. 8
4.2 Construction Design ............................................................................................................... 8
4.3 Pig-ability ............................................................................................................................. 9
4.4 Valve Body, Bonnet / Top Cover and End Closure Design ................................................. 9
4.5 Ball ...................................................................................................................................... 9
4.6 Seats and Seal Rings .......................................................................................................... 9
4.7 Stem, Stem Seal and Drive Train ........................................................................................ 10
4.8 Bearings .............................................................................................................................. 10
4.9 End Connections ................................................................................................................. 10
4.10 Body Connections ............................................................................................................... 11
4.11 Operation ............................................................................................................................. 11
5 MATERIALS OF CONSTRUCTION
5.1 General ............................................................................................................................... 12
5.2 Valve Body, Bonnet/Top Cover and End Closure ................................................................ 12
5.2.1 Valve Body, Bonnet/Top Cover Materials ..................................................................... 12
5.2.2 Weld Ends ................................................................................................................ 12
5.2.3 Duplex Steel Manufacture .......................................................................................... 13
5.3 Valve Trim ........................................................................................................................... 14
5.4 External Bolting ................................................................................................................... 14
5.5 Welding ............................................................................................................................... 14
5.6 Trim Surface Treatment ...................................................................................................... 14
6 NON-DESTRUCTIVE EXAMINATION
6.1 Non-destructive Examination (NDE) .................................................................................... 15
6.2 Repair of defects Detected by Non-destructive Examination .............................................. 16
7 PERFORMANCE TESTING
7.1 General ............................................................................................................................... 17
7.2 General Test Requirements ................................................................................................ 17
7.3 Hydrostatic Body Test ......................................................................................................... 18
7.4 Hydrostatic Seat Leak Tests ................................................................................................ 18
7.5 Pneumatic Seat Test - For Gas Service Valves Only .......................................................... 18
7.6 Operation torque test ........................................................................................................... 19
7.7 Integrated performance testing ............................................................................................ 19
7.8 Re-tests ............................................................................................................................... 19
8 INTERNAL PROTECTION
9 COATINGS
9.1 Painting & Coatings ………………………………………………………………………………….. 20
10 QUALITY ASSURANCE AND CONTROL
10.1 General ............................................................................................................................... 21
10.2 Inspection and Test Plan ..................................................................................................... 21
10.3 Special Process Procedures ............................................................................................... 21
10.4 Quality Records ................................................................................................................... 21
10.5 Final Inspection ................................................................................................................... 22
10.6 Verification ........................................................................................................................... 22
10.7 Certification ......................................................................................................................... 22
11 MARKING
13 ~ 21 General Requirements………………………………………………………………………………24~40
1 INTRODUCTION
1.1 General
Khalda Petroleum Company (KPC), a joint venture between Apache Corp and the
Egyptian General Petroleum Corporation (EGPC), plan to develop the HIGH
PRESSURE GAS WELLS in the Western Desert of the Arab Republic of Egypt.
The HIGH PRESSURE GAS WELLS field is planned to initially consist of wells linked to
a manifold. Export of raw gas from this manifold will be via a new pipeline to a manifold
at Main area, followed by new pipelines to two existing gas-processing plants.
1.2 Scope of Document
This specification defines the minimum requirements for the manufacture; inspection
and testing of 22% chromium duplex stainless steel (UNS S31803) ball valves for the
facilities on the High pressure gas wells Development Project.
1.3 Definitions
For a comprehensive list of definitions refer to the purchase order under which this
specification has been issued.
1.4 Abbreviations
1.5 Compliance
Compliance by the VENDOR with this specification shall not relieve him of his
responsibilities to supply 22% chromium duplex stainless steel ball valves suited to
meet the specified requirements and/or local codes governing health and safety.
The VENDOR shall notify the COMPANY in writing, of any proposed deviation from this
Specification. The COMPANY's decision in respect of concession requests will be final.
The VENDOR shall continually verify the quality and fitness for purpose of the valves,
and shall propose appropriate actions/measures if any aspects of manufacture are
found to be unsatisfactory.
The VENDOR shall demonstrate to the satisfaction of the COMPANY that his activities
within the scope of this document are in accordance with an internationally recognized
quality system such as BS EN ISO 9001-2000. The VENDOR shall submit to the
COMPANY for review and approval, a Quality Plan and procedural specifications prior
to commencement of work.
The Quality Plan shall define all sub VENDOR’s involvement in the work. This
specification shall not relieve the VENDOR of his obligations to comply with the
requirements of the Contract.
1.7 Safety
Safety is paramount. All work shall be performed in accordance with the safety
requirements listed in the contract documentation. All personnel representing the
COMPANY shall complete a VENDOR safety induction, prior to starting work at the
VENDOR or their sub-VENDOR’s premises.
2
2 SPECIFICATIONS, CODES AND STANDARDS
.1 General
The latest revision of the following codes and standards shall be used unless otherwise
indicated by the COMPANY.
VENDOR shall be required to notify COMPANY in writing of any proposed deviations from
the applicable standards, codes and regulations.
All ball valves shall comply with the requirements of API 6D/ISO 14313 and all
supplemental requirements of this Specification. In the event of conflict between API
6D/ISO 14313 and this specification, the most stringent requirements shall apply.
2.2 Standards and Codes
ASME B31.8 – 2003 Gas Transmission and Distribution Piping Systems
ASME B31.3 – 2002 Chemical Plant and Petroleum Refinery Piping
API 6D/ISO 14313 Pipeline Valves
ASME B16.10 Face to Face and End to End Dimensions of Valves
ASME B16.25 Butt Welding Ends
ASME B16.34 Valves - Flanged threaded and welding ends
ASME B16.5 Pipe Flanges and Flanged Fittings
ASME V Boiler and Pressure Vessel Code - Non-Destructive Examination
ASME VIII Div 1 Boiler and Pressure Vessel Code – Rules for Construction of
Pressure Vessels
ASME VIII Div 2 Boiler and Pressure Vessel Code – Rules for Construction of
Pressure Vessels – Alternative Rules
ASME IX Boiler and Pressure Vessel Code – Qualification standard for
Welding and Brazing Procedures
ASTM A182 Specification for forged or rolled alloy-steel pipe flanges, forged
fittings, and valves and parts for high temperature service
ASTM A193 Specification for Alloy Steel and Stainless Steel Bolting
ASTM A194 Specification for Carbon Steel and Alloy Steel Nuts
ASTM A890 Standard Specification for Castings, Iron-Chromium-Molybdenum
Corrosion-Resistant, Duplex (Austenitic/Ferritic) for General
Application
ASTM A923 Standard Test Methods for Detecting Detrimental Intermetallic
Phases in Wrought Duplex Austenitic/Ferritic Stainless Steel
ASTM E562 Standard Practice for Determining Volume Fraction by Systematic
Manual Point Count
BS 3382 Specification for electroplated coatings on Threaded
components - Part 2, Zinc on steel components
API 598 Valve Inspection and Testing
BS 6755 Testing of Valves
BS 7079 Preparation of Steel Substrates Before Application of Paints and
Related Products
BS EN 10204-2004 Metallic Products - Types of Inspection Document
BS EN ISO 9001-2000 Quality Management System
SAE AS 4059 Aerospace Fluid Power - Cleanliness Classification for Hydraulic
Fluid
The valves shall meet the requirements of the design and operating data given in the
Valve Data Sheets and valve schedule.
All valves shall be suitable for infrequent operation, assume 5 times every 5 years. The
valves shall operate satisfactorily at all times during their design life.
4.1 General
Test pressure.
Welding procedure for each type of weld, including weld joint factor. Any conflict between this
specification and the information contained in the equipment’s drawings must be
communicated, in writing, to the COMPANY in order to obtain the pertinent approval.
Any conflict between this specification and the information contained in the equipments
drawings must be communicated in writing to the COMPANY in order to obtain the
pertinent approval.
4.2 Construction Design
The valve design shall be such that a build-up of rust, sand and other line debris will not
prevent the free movement or proper functioning of valve components when being
operated from either the open or closed position.
Where required electrical continuity shall be achieved between the ball and the body via
the valve stem connection to the actuator. The valve body shall be designed such that
localized bimetallic corrosion of the body shall not occur to the detriment of the sealing
surfaces or valve operation.
The valves shall not have internal end stops. Normal positional operations shall be
conventional in that closing shall be clockwise when viewed from above.
The valve design shall be such that self-closing due to vibrations etc. shall not occur.
One or more dowels shall be used for all components that require precise reassembly to
ensure accuracy in positioning and ball rotation. Where there is the possibility of
replacing a component in the wrong position then asymmetric dowels shall be used.
Additionally, identifying markers or protrusions shall exist on the exterior of the valve to
assist re-assembly in the correct position.
4.3 Pig-ability
Where specified in the data sheets, valves shall be capable of being pigged and
scraped regularly, without debris being pushed between the valve seats and the ball.
The bore of the fully open valve shall present as smooth a profile as possible to a
passing pig or scraper. Full bore valves shall be designed to allow pigging in both
directions. All other valves will not be subject to pigging operations.
4.4 Valve Body, Bonnet / Top Cover and End Closure Design
The valve body and other pressure containing parts shall be designed in accordance
with ASME VIII Division 1 or 2, including material maximum allowable stresses and
meet the minimum wall thickness requirements of ASME B16.34.
The completed valve assemblies shall be provided with lifting lugs suitably certified for
the maximum lift weight. The lifting lugs shall enable the COMPANY to handle the valve
assemblies safely on delivery. Attention should be paid to the location and design of the
lifting lugs when large gears or actuators are incorporated. All lifting lugs shall be
painted yellow, and marked on the valve close to the lug “LIFT HERE”.
Bonnet and/or end flange bolting and nuts shall be designed such that suitable bolt
tensioning equipment can be used during assembly. Sufficient access shall therefore be
available to deploy, operate and retrieve tensioning jacks at each nut location.
4.5 Ball
The valves shall have self-lubricating trunnion mounted balls. A hole in the ball or a
relief valve in the body, for pressure relief is not permitted.
4.6 Seats and Seal Rings
The primary seal shall be metal-to-metal (hard); the secondary seal shall be a polymer
(soft, e.g. PTFE/ PEEK). Nylon is not an acceptable secondary seal material. Seat and
seal material shall be compatible with the process fluid, including benzene, toluene,
xylene and methanol.
The seat shall be configured so that it is not damaged during pigging operations.
The VENDOR shall demonstrate by means of calculations or tests that the seat material
can satisfactorily withstand the loadings experienced in service at pressure
and temperature limits specified, including exposure to the full pipeline system
hydrostatic test pressure in the closed position.
Body cavity shall be provided with self-relieving (SR) seat ring(s). A hole in the ball or a
relief valve in the body, for pressure relief is not permitted. See also 4.5 of this
specification.
The VENDOR shall demonstrate by calculations, to be provided by VENDOR that the
seat spring force is of sufficient magnitude to prevent pigging from pulling the
downstream seat rings off the ball.
The design of the seat and seals shall be such that there is no requirement for
adjustment either during the initial setting up or in service.
Unless otherwise agreed, the seat material shall be the same as that used for the ball.
The VENDOR shall demonstrate that galling will not take place. This shall be by
provision of test or historical data which is relevant to the ball /seat design and materials
of the valves being provided. The ball and seat shall be coated as specified in section
5.6.
Spring materials shall be galvanically compatible with those of the seat rings.
The design of all elements of the drive shall be in accordance with API 6D/ASME
B16.34.
Splines on the stem are the preferred method of drive transmission. A master spline
shall be in line with the pipeline when the valve is in the fully open position. The gearbox
or actuator shall be aligned with the pipeline axis. The valve operator shall be suitable
for rotational positioning in 90-degree increments about its axis (i.e. four possible
positions of the gearbox/actuator on the valve). Energized seals shall be provided to
achieve sealing at the stem over the range of internal and external pressures and
temperatures specified by the Valve Data Sheets. All stem seals shall be of a
maintenance free, anti-blowout design and material and shall be replaceable in the
event of malfunction.
The VENDOR shall ensure that there is no risk of galling at the stem.
4.8 Bearings
Polymeric bushes are the preferred type of stem and trunnion bearings. They shall be
corrosion-resistant.
Alternative types of bearings may be used with prior approval of the COMPANY.
Thrust bearings shall be provided to prevent vertical motion of the ball under
pressure. Polymeric materials shall be used.
4.9 End Connections
End connections shall be as per the Valve Data Sheet. When specified in the Valve
Data Sheet, valves shall be supplied with pup pieces supplied by the VENDOR.
These shall be welded to the valve body according to section 5.5. Pup pieces, where
specified in data sheet, shall comply with the valve schedule.
4.10 Body Connections
All vent and drain connections, called up by the data sheets, shall be terminated with a
ball valve.
The ball valve (including trim) and any pipe work from the main valve to the vent /
drain ball valve shall be of an equivalent material to the main valve.
The vent / drain valve shall be terminated with a captive screwed plug.
4.11 Operation
Each ball valve shall be provided with a means of being operated either manually or
automatically with a permanent actuator as specified in data sheet.
The local indicator shall be in line with the pipeline when the valve is in the fully open
position and transverse when in the closed position.
The manual operating drive train shall be sized for applying a minimum of 3 times the
design torque/force required to operate the valves under all conditions (i.e. with/without
pressure differential across the ball). The maximum force required at the hand wheel or
lever to apply the breakaway torque or thrust shall not exceed 250 N. This shall be
shown by calculation and the calculation shall be presented as requested in SDRL.
5 MATERIALS OF CONSTRUCTION
5.1 General
All materials used in the construction of the valve(s) shall be sourced from Western
European, North American or Japanese manufacturers. Materials shall be according to
the Valve Data Sheets and this Specification or COMPANY agreed equivalent. The
VENDOR shall propose materials for all components not specified in this specification
and the Valve Data Sheets for COMPANY approval. Only COMPANY approved
materials shall be used.
Materials shall be suitable for the specified conditions and shall be selected so as to
avoid galvanic corrosion, which may be detrimental to the integrity of the valve. In
addition, the materials of the valve and components shall be compatible with the
application of external cathodic protection.
All materials employed by the VENDOR in the construction of the valve shall be
traceable to source and shall be appropriately certified by the material manufacturer.
Material certificates shall form part of the Data Book.
All pressure containing and pressure retaining components shall be subject to
mechanical testing, including the valve body, bonnet / top cover, end closures, ball,
stem and seats and bonnet / top cover and end closure bolting.
The COMPANY’s appointed representative shall witness testing. The Vendor shall notify
the COMPANY’s representative two weeks prior to date of testing to allow attendance.
All process wetted parts shall be suitable for process conditions envisaged during the
life of the field, including those due to hydrostatic testing and pre-commissioning
activities as defined in the Valve Data Sheets.
5.2 Valve Body, Bonnet/Top Cover and End Closure
The valve body, bonnet / top cover and end closure materials shall be forged or cast
22% chromium duplex stainless steel to ASTM A-182 F51 or ASTM A-890 4A as
specified on the attached Valve Data Sheets.
Fabrication of body, bonnet / top cover and end closure from plate is not acceptable.
End connections may be integral with the valve body, bonnet / top cover, end closure or
weld neck fittings.
5.2.2 Weld Ends
If weld neck fittings are used for end connections, suitable test rings from the same
material heat and from the same heat treatment batch shall be required for field weld
procedure qualification testing by others in accordance with Section 5.5 of this
Specification. When a test ring requirement is stated in the Valve Data Sheets the
VENDOR shall be responsible for the supply of the test rings.
22% chromium duplex stainless steel shall be manufactured by one of the following
process routes:
(a) Blast furnace refining followed by decarburization using the Argon Oxygen (AOD)
or Vacuum (VOD) processes. Where necessary, final adjustment of molten metal
analyses and condition shall be carried-out using the Ladle Treatment (LT)
process.
(b) Electric Furnace melting and refining, followed by AOD or VOD and, if necessary,
LT.
22% duplex stainless steel shall have a pitting resistance equivalent (PRE n) of 35
minimum,
Where, PREn = Cr + 3.3xMo +16xN
As demonstrated by material test certificates
Note: quantities of alloying elements are weight percentages (%w).
Castings and forgings shall be fully heat-treated and shall be supplied in the solution-
annealed condition. Heat treatment and control procedures shall be approved by the
COMPANY prior to starting work.
The VENDOR shall submit the proposed scope of mechanical testing to the COMPANY
for approval. Tests shall be such as to demonstrate that the material is suitable for the
specified service. All mechanical tests shall be carried-out on material in the final heat-
treated condition. A tensile test shall also be carried out for information at the maximum
temperature specified in the data sheets
Charpy V – notch impact testing shall be carried out using specimens transverse to the
principle direction of grain flow, with notches perpendicular to the surface. Unless
otherwise specified in the Valve Data Sheets the Charpy V – notch energy shall be 70
Joules minimum average of 3 specimens and 58 Joules minimum individual, when
tested at the minimum design temperature.
In addition, metallography of specimens at a minimum magnification of 400 times shall
be carried-out to confirm a correctly balanced microstructure. The microstructure shall
be essentially free from grain boundary carbides, nitrides and
intermetallic/transformation phases such as sigma and shall be classified in accordance
with ASTM A923 “Unaffected Structure”. Annotated photographs of the microstructure
shall be supplied with the documentation.
The ferrite/austenite ratio shall be determined according to ASTM E562 or COMPANY
agreed equivalent. The ferrite content shall be in the range 35 to 55%.
A ferric chloride test shall be performed in accordance with ASTM G48, method A or
ASTM A923 method C with a test temperature of 25°C.
6 NON-DESTRUCTIVE EXAMINATION
The VENDOR shall submit inspection and NDE procedures for COMPANY approval
before the start of manufacture.
NDE shall be conducted in full accordance with the requirements of Annex B of API
6D/ISO 14313 as a minimum, together with the following requirements:
• Cast Components
Volumetric NDE shall be by 100% radiography of accessible areas for every
valve in accordance ISO 14313 annex B, section B.3. Surface NDE shall be by
Liquid Penetrate testing of castings on 100% of surface area in accordance with
section B.7.
• Forgings
Volumetric ultrasonic testing of forging and plate on 100% of surface area each
pressure containing component to be in accordance with annex B section B-8
of ISO 14313.
• Welds
Welds shall be tested in accordance to ISO 14313 Annex B section B 10 for
radiographic testing of weldments on 100% of weld or section B.11 ultrasonic
testing of full penetration weldments on 100% weld
.
NDE shall be carried-out by operators qualified to ASNT-TC-1A level 2 minimum or
COMPANY agreed equivalent. Level 3 qualified personnel shall be responsible for
preparation of NDE procedures and shall be available at all times.
Acceptance NDE shall be carried-out after final heat treatment and machining to an
adequate surface finish for testing, where appropriate. Any preliminary NDE conducted
prior to heat treatment shall be at the VENDOR's discretion. Where necessary, the
surface shall be prepared by shot-blasting or grinding.
Surface examination by visual and dye penetrant inspection (DPI) shall be conducted on
the entire, accessible internal and external surface of the product or component in its
finished form. Small diameter holes shall be examined to a depth at least equal to their
diameter.
For castings examination shall be by radiography. Each single pressure-containing
component is to be tested. Where testing of duplex materials is performed by ultrasonic
methods all testing shall be qualified. If qualification is unsatisfactory, then radiography
shall be used.
Pup piece to valve body welds shall be subject to NDE in accordance with the
requirements of specification No 05-2520-01-P-1-030
Prior to any repair, COMPANY shall be notified in writing of the nature and extent of the
repair and the repair proposals. All repairs shall be according to written procedures,
which have been reviewed and accepted by the Company. These shall include details of
defect removal methods, weld repair procedure specifications, dimensions of
excavations, qualifications and methods of NDE as appropriate._ Qualification of repair
welding procedure specifications shall be according to ASME IX.
Minor surface discontinuities such as slivers, sharp notches, gouges, scores, pits or
machining marks may be repaired by grinding or machining provided the component
thickness is not reduced below the design minimum which shall be stated in Vendor
calculations. The machined or ground areas shall be carefully dressed to ensure a
smooth transition to the surrounding surface of the component. Removal of the
discontinuity shall be confirmed by NDE of the same type that detected the original
discontinuity. Ultrasonic thickness measurement using suitable probes shall be carried-
out on repaired areas to ensure that the minimum thickness is maintained.
Inspection of repair welds shall be done using the same methods that were used in
inspection of original weld and shall be subject to the same NDE and acceptance criteria
as was used to detect the original discontinuity. Vendor shall qualify procedures.
7 PERFORMANCE TESTING
7.1 General
The VENDOR shall propose detailed performance test procedures for each of the
following tests for review and acceptance by COMPANY prior to the commencement of
any testing. This shall also include the sequence of testing as listed below.
Every valve shall be subject to the hydrostatic, pneumatic body and seat tests as detailed
below. The COMPANY representative shall witness the tests for each valve during the
normal production times; i.e. valves shall not be taken out of the normal production line
production line for testing purposes.
Valve ends shall be free of longitudinal restraint during pressure testing and should be
restrained by blind flanges to provide pressure, temperature, vent and drain
connections.
Test medium for gas tests shall be air or nitrogen or nitrogen/helium mixture.
Water used for hydrostatic body and seat tests shall be fresh, clean and contain a
suitable water-soluble rust inhibitor and a suitable wetting agent.
The hydrotest water temperature shall be between 3°C-20°C. During the test, the water
temperature shall not vary by more than ±2°C from the start temperature.
Test Pressure
Duration
The VENDOR shall be responsible for supplying all necessary fittings and materials for
testing.
During and after all tests, the ball shall be examined for free movement and damage.
After completion of leak test, a check is to be carried out to ensure correct alignment of
ball and valve bore.
The seat on each side of the ball shall be subject to separate hydrostatic seat tests in
accordance with API 6D and/or BS EN 12266-Parts 1 and 2 at 1 barg, 5.5 barg and 1.1 times
the pressure rating of the valve.
The valve shall be depressurized and the ball valve closed. The uppermost vent on the body
cavity shall be opened and excess water shall be allowed to drain from the cavity to the lowest
level of the vent.
The outer section of the valve adjacent to the pressure seat shall be pressurized and held for 30
minutes. The leakage rates across the valve shall be measured after a stabilization period of 10
minutes and shall be repeated after two more 10-minute intervals. The leakage shall be
measured at the downstream side, preferably by a pipette to avoid the meniscus effect.
Upon completion of this test, the valve shall be depressurized and the test repeated on the
other seat.
For gas service valves, the seat on each side of the ball valve shall be subjected to separate
pneumatic seat tests at 1 barg and 5.5 barg. Every valve shall be subject to a pneumatic seat
test.
After completion of leak test, a check is to be carried out to ensure correct alignment of ball and
valve bore.
For soft seated ball valves the acceptable gas leakage rate shall be in accordance with
BS EN 12266 Rate A.
The valve shall be depressurized and the ball closed. The differential pressure
equivalent to the pressure rating of the valve specified in the valve Data Sheet shall be
applied. The torque shall be measured whilst the valve is being opened (breakaway)
whilst running and upon re-seat.
The test shall be repeated five times for each seat and the values recorded. The values
shall fall within the range given in VENDOR's design documentation. The VENDOR
shall confirm that the variation between tests on similar valves does not exceed 20%.
The VENDOR may, at its discretion, opt to conduct a torque test at the end of each seat
test.
Where valves are to be supplied with associated actuators and/or gearboxes, VENDOR
shall perform an integrated performance test including, but not limited to, the following:
- Actuations against full valve differential pressure with maximum and minimum
actuator supply pressures.
- Setting of remote electrical and/or mechanical position indication systems.
- Assembly/disassembly tests on valve/actuator/gearbox units.
7.8 Re-Tests
If any of the above tests fail, the valve will be rejected. Rejected valves, which the
vendor considers can be repaired, shall be repaired and a report issued for
consideration of re-testing. The extent of the re-test programme shall be subject to
review and acceptance by COMPANY in each case prior to the start of any re-testing.
8 Internal protection
Full details of internal coating or substrates, applied to provide temporary protection
following completion of valve manufacturing and testing and during transportation and
site storage, is specified in protection of goods during shipment specification 05-2520-
01-M-1-003.
9 COATINGS
The external non-duplex stainless steel components shall be coated after completion of
all pressure tests.
The valves and actuators shall be coated as specified in the data sheets.
The VENDOR shall submit a surface preparation and painting / coating system for
review and approval by the COMPANY.
The painting & coating systems shall be suitable for the environmental conditions in the
Egyptian Desert.
The painting & coating system, which are to be used on the entire exterior of carbon
steel components, shall be as follows:
Coating of Below Ground Valves
Shall be with a multi component liquid coating system to include:
• Surface preparation by blasting to SA 2½ and solvent cleaning of any
contaminants shall be undertaken
• MCL system approved by the COMPANY
The coating system shall be suitable for a 25-year design life in the Egyptian desert
environment.
10.1 General
All certification, test results, reports and any other documentation submitted to
COMPANY shall be written in the English language.
The VENDOR shall establish and maintain a formal system to control the issue,
production, registration, modification and filing of all documentation.
The VENDOR shall perform all document management under a quality assurance
system in accordance with ISO 9001-2000.
Prior to commencement of the work, the VENDOR shall prepare a written inspection
plan that describes the inspection to be performed. The inspection and test plan,
reference procedure and changes shall be subject to acceptance by COMPANY.
The VENDOR shall establish and maintain control of all special processes that are
essential to production, inspection or safety. Equipment, processing environment and
the VENDOR's personnel shall be subject to appropriate qualifications, with certification,
to the satisfaction of the COMPANY.
10.6 Verification
All VENDOR inspection systems shall be subject to evaluation and surveillance by the
COMPANY to ensure that they meet the requirements of this specification and the contract.
All VENDOR operations required by this specification are subject to:
Procedures compliance checking at unscheduled intervals to determine that the VENDOR's
inspection system is effectively applied.
Product verification to determine compliance with control requirements. The method of
verification is at the discretion of the COMPANY.
No valves shall be released to COMPANY, unless VENDOR has been issued with an
inspection release note (IRN) by COMPANY. A copy of the IRN shall form part of the delivery
notes accompanying each dispatch of valves.
10.7 Certification
Certification and document requirements for the supply of 22% chromium duplex stainless steel
ball valves shall be according to the SDRL.
A copy of the certification shall be shipped with each valve.
Material certificates to BS-EN-10204-2004 Type 3.1 shall be required for all pressure containing
parts. All other items including the drive train and bolting shall be provided with certification
according to BS-EN-10204-2004 Type 2.2.
11 MARKING
Each valve shall be identified by a unique COMPANY tag number. This number shall appear on
all drawings and correspondence and shall appear on the Vendor’s standard nameplate. The
same numbers shall be stenciled on each packing case, with size and rating. Identification
markings shall comply with API 6A and include the following information:
COMPANY's tag number.
COMPANY's contract/order number.
Size and rating.
Manufacturer's trade name and address.
Date of manufacture.
Date of delivery.
Manufacturer's number.
Manufacturer's unique serial number
Certified weight.
Where more than one item is produced against a single order number, they shall be identified
separately from the start of the production through to completion.
12.1 Handling
The VENDOR shall be responsible for design and manufacture of a handling frame for
protection during shipping/transportation and testing of valves, with actuators or
gearboxes as applicable. The frame shall be designed to ensure that the actuator is
always in the vertical position (i.e. as-installed).
All other handling of valves shall be carried out using broad non-metallic belt slings.
All packing, handling and shipping shall be carried out according to the requirements of
this specification.
All valves which have actuators shall be shipped with the actuator attached and the ball
in the fully open position.
The VENDOR shall provide details of his proposed packing specification for the valve
and actuator assembly for acceptance by COMPANY.
12.3 Storage
The equipment may be held in storage. Equipment shall be suitable for storage for a
period of up to six months.
In the event of long-term storage of greater than six months, VENDOR shall prepare a
'Long Term Preservation and Storage Procedure’, which will be subject to acceptance
by COMPANY. Valves will then be preserved and stored in compliance with the agreed
procedure.
The valve balls shall be left in the fully open position during transit and storage.
The VENDOR shall define in the handling and shipping procedure, the space
requirements and essential preventative maintenance procedures which may need to
be implemented to maintain the integrity of the warranty.
13 DOCUMENTATION REQUIREMENT
Electronic Files
Once the documentation is accepted by the OWNER’S REPRESENTATIVE /Third party
inspection (TPI), the VENDOR shall within 3 days of acceptance, issue an Adobe
Acrobat pdf version of the documentation to the OWNER’S REPRESENTATIVE /Third
party inspection (TPI) by e-mail. Whenever documentation is updated, the VENDOR
shall reissue the updated version within 2 days of acceptance.
All Data Book documentation shall be submitted as native format (e.g. MS Word) and
Adobe Acrobat pdf files on CD, in addition to the stamped hard copies. The VENDOR
shall put in place any necessary copyright licenses that may be required for such digital
reproduction.
13.4 Communications
All communications whether written or spoken shall be in the English language. The
VENDOR shall maintain at all Sites a supervisor who is fluent in English.
13.5 Correspondence
All formal technical correspondence under the Purchase Order shall be addressed and
directed between the OWNER and the VENDOR's Representatives. Formal
correspondence is deemed to include letters, telefaxes and minutes of meetings,
provided always that such items carry unique reference numbers in the following
format:
PO-XXX-YYY-ZZZ-A.
Where:
PO Khalda Purchase order reference.
XXX Denoting OWNER’S REPRESENTATIVE /Third party inspection (TPI) name of
originator
YYY Denoting OWNER’S REPRESENTATIVE /Third party inspection (TPI) name of
recipient
ZZZ A sequential number A designates correspondence type (i.e. Letter, telefax
etc.).
Oral or non-formal communications of instructions or information in connection with the
Purchase Order shall be confirmed in writing using formal correspondence.
The VENDOR shall freely provide all progress and other related information to the
OWNER’S REPRESENTATIVE /Third party inspection (TPI) or to the designated forum.
The VENDOR shall issue a progress report every 2 weeks to OWNER’S
REPRESENTATIVE /Third party inspection (TPI) which details the current purchase
order status and areas of concern.
Formal project meetings between the VENDOR's and the OWNER’S
REPRESENTATIVE /Third party inspection (TPI)'s project personnel shall take place
periodically at the VENDOR’s works.
Brief minutes will be taken by the OWNER’S REPRESENTATIVE /Third party
inspection (TPI) and distributed to the VENDOR within 5 working days.
All actions noted shall be carried out as soon as reasonably practicable.
More frequent meetings may be held at the VENDOR’s works if issues arise that
require a meeting to resolve.
The Data Book index shall be based upon the applicable SDRL. The VENDOR shall
submit the Data Book index for approval by the OWNER’S REPRESENTATIVE /Third
party inspection (TPI).
The VENDOR shall ensure that all documents produced by or on behalf of VENDOR are
maintained and are available in an electronic format. The VENDOR shall ensure that all
information is filed in a form that will provide efficient and easy transfer to the OWNER’S
REPRESENTATIVE /Third party inspection (TPI) at the project closeout.
The draft Data Book shall be issued in accordance with the SDRL for review & stamp by
the OWNER’S REPRESENTATIVE /Third party inspection (TPI). The final Data Book
shall be issued within 2 weeks of OWNER’S REPRESENTATIVE /Third party inspection
(TPI) comments being returned.
The VENDOR shall supply the entire Data Book, once accepted, in the following forms
unless agreed otherwise by the OWNER’S REPRESENTATIVE /Third party inspection
(TPI):
Hard copy (1 copy);
Electronically in indexed Adobe Acrobat pdf file format on CD ROM or DVD.
Notes:
1. Submissions requirements, quantities, formats & timings to be agreed prior to contract award.
2. “For Review” indicates review by Owner’s Engineers only.
3. “To be verified” indicates review by Owner’s Inspection.
ISPM-15 Requirements
Compliance with ISPM-15 for wood packaging materials allows for two treatment
options:
Heat Treatment (HT): Wood packaging material should be heated in a
schedule that achieves a minimum core temperature of 56ºC for a minimum of
30 minutes.
Methyl Bromide (MB) Fumigation: The wood packaging material should be
fumigated with methyl bromide.
NOTE: ISPM 15 requirements apply to all species of coniferous (softwood) and non-
coniferous (hardwood) packaging materials.
15.3 Marking
Standard international shipping and handling symbols should be used, but any special
handling instructions should be marked both in English and also in Arabic if possible. In
addition ISPM 15 markings as shown in the typical example below should be applied to
fumigated wooden cargo and/or cargo in wooden boxes.
Marking of Packages
European Union
From 1 March 2005 new landing requirements apply for wood, wood products and
wooden packaging material arriving in the European Community from all countries,
except Switzerland. The landing requirement does not apply to wood, wood products
and wooden packaging material which is simply moving from one EU member State to
another. Additionally there is no phytosanitary certificate requirement for wooden
packaging material arriving in the EC, which is ISPM15 compliant provided that the
certification is shown via the application of the ISPM15 wood mark (see above).
All WPM, such as boxes, crates, pallets, which are made using any un-manufactured
wood products, MUST meet the new requirements and be either heat treated or
fumigated with Methyl bromide under an officially approved programme and carry the
internationally agreed mark.
USA, Canada and Mexico
The USA, Canada and Mexico have taken up the ISPM 15 requirements, these have
been in force since 16 September 2005.
15.5 Air fright
Air fright packages shall conform to ISPM15 requirements, otherwise the package
standards as outlined in these instructions, are for ocean freight shipments only and
don’t apply to air fright shipment. Vendor’s standard international shall be provided for
air shipments, the vendor to obtain owner’s approval of its standard international
packing.
33/40 Specification for HP Duplex Ball Valves
01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects
When consolidating materials in a box or crate, items shall be packed or nested to reduce volume
as much as possible. All items shall be braced and/or cushioned as necessary within the
container to prevent damage from shock, vibration and rough handling. Finished and painted
surfaces will be protected from abrasion.
Small items and spare parts not secured to main item shall be separately boxed with box properly
identified as to its main item.
It is necessary that all shipping containers be tightly packed. Where voids appear, they will be
filled with cushioning material or securely blocked off to prevent any movement of contents.
Woodwool may be freely used for packing. Restricted materials which may not be used include:
Used sacks and sacking - including jute and hessian.
Hay and straw - including straw envelopes.
Rice Husks.
Agricultural waste products.
Any packing materials which may have come into contact with animals or soil.
Grass and similar matting.
(a) Articles of peat.
(b) Used wool packs and wool packers.
Containers shall be packed in such a manner to ensure an even distribution of weight within the
case. All cases will bear warning signs on the outside denoting the centre of gravity and sling
marks. Top-heavy containers will be so marked as either “Top-Heavy” or “Heavy End”.
Heavy items should be securely blocked and braced to prevent damage to lighter materials
packed in the same box. Heavy items, where possible, should be packed on the bottom with
lighter items on top.
Palletizing
Items which are not crated or boxed and are impervious to damage from moisture, water handling
and external damage, which can be conveniently secured to a pallet to facilitate handling, shall be
palletized.
Bundling
All items shall be segregated to length and size and bundled into units not to exceed 1134 kg
(2500 lbs.) unless previously approved by OWNER. Apply steel strap with a stretching tool and
secure with crimped steel seals spaced up to 92 cm (36”) apart.
16.1 Boxes
The construction and reinforcing of a wooden box depends upon the size of the box and the
weight of its contents. Following are minimum requirements for various boxes.
Plywood boxes shall be constructed with uprights set on 60.9 cm (2-foot) centres. All
seams should be backed with an upright or brace.
(c) 450 to 4500 kg or 1000 to 10,000 lbs
Box shall be constructed with a 10.2 x 10.2 cm (4”x4”) nominal skid base, 5.1 cm (2”)
nominal floor, 2.5 cm (1”) nominal lumber or 1.6 cm (5/8”) plywood sheathing, with
cleated ends. Top and sides to be diagonally braced, with corner posts, bracing and
stiffening members of 5.1 x 10.2 cm (2”x4”) nominal lumber. Load bearing members
shall be placed as needed. Top and upper edge members of large or heavy boxes shall
be reinforced with 10.2 x 10.2 cm (4”x4”) or 10.2 x 15.2 (4”x6”) spreaders to prevent
crushing of boxes when lifting-slings are used.
(d) Strapping
All boxes must be strapped with a minimum of 2 steel bands running parallel to skids.
1.9 cm (¾”) banding may be used on boxes less than 181 kg (400 lbs.) 3.2 cm (1-1/4”)
or 5.1 cm (2”) banding must be used on boxes or crates over 181 kg (400 lbs).
Any equipment that should be sealed off from the atmosphere shall be protected in one or more of the
following manners:
Wrapping in 3M “cloth wrap” with all lines, joints, and folds sealed with waterproof adhesive.
Packing in a totally enclosed box lined with Kraft paper impregnated with Shell “VPI-270”. The
Kraft paper shall have a waterproof backing.
Packing in an airtight carton after dusting paper wrapped equipment with “VPI-250”, or after
suspending sacks of “VPI-250” within the equipment.
Enclosing within a waterproof heat-sealed carrier bag or shroud, or a sealed plastic film.
Vapor phase inhibitors equal to the above specified; Shell “VPI” products may be substituted with
OWNER’s approval.
Equipment that cannot be sealed off from the atmosphere by wrapping or boxing shall be protected by
coating the unpainted surfaces with the following:
(c) Esso Rust-Ban 339 rust preventative for light oily surface protection.
Flange openings shall be coated with a layer of anti-corrosive material then closed off with wooden,
metallic or plastic, fastened in place with tape or non-rusting devices.
Caution shall be exercised in applying preservatives so that items fabricated of leather, mica, rubber,
and similar material, are not coated with the preservative compound because of the damaging effect
on such items.
Shipping containers shall be constructed and sealed in a manner that shall provide maximum
protection from pilferage and theft.
After rust-treating and sealing, equipment shall be boxed and crated as specified in Section 3.0 of this
specification.
Shell Company VPI-250 or 270 can be applied dry by use of a De Vilbiss Company Floc Gun or
other dusting device. VPI powder should be dispersed over exposed metal surfaces or suspended
in finely meshed sacks at intervals within the equipment. For sensitive or precision operating
equipment, the “VPI-250” should be suspended in sacks within the equipment housing.
Since VPI can protect metal only 12 inches distant from its location, it should be fairly evenly
dispersed or placed in small porous sacks suspended within 12 inches of the surface to be
protected. Dosage is as follows:
VPI is a salt that liberates nitrite ions which are deposited on the exposed metal surfaces and
gives protection against oxygen and moisture. Excellent protection is given ferrous metals and
most non-ferrous materials. VPI does not provide protection for pure lead, solder, or pure
antimony.
VPI, when inhaled, may irritate the nose and throat and leave a bitter taste in the mouth. There is
no harm in breathing VPI and there are no cumulative toxic effects.
Esso Rust-Ban in most cases can be either brushed or sprayed on metal surfaces or parts can be
dipped. The following is a description of the Rust-Ban to be used:
394 Soft Tan 0.001” 1 year inside 950 sqft/gal Solvent film
339 Clear oily 0.0003” 6 months indoor 400 sqft/gal Solvent film
Some substitutes for Esso Rust-ban are as follows.
Esso Pennsylvania
18 INSTRUMENTS
Board-mounted and all electronic instruments shall be shipped to the panel fabricator enclosed in
plastic bags with VPI 250 in protective cartons. All these instruments will be unpacked and
mounted on the board at the panel fabricator’s shop for check-out.
When the panel-board check-out is complete, all the instruments will be enclosed in the original
plastic bag with additional VPI 250 added, and placed in their original cartons before boxing in
accordance with Section 3.0.
Panelboards consist of painted steel plates on a steel framework. To prevent rusting, the
panelboard sections shall be packed in boxes in accordance with Section 3.0, that have first been
lined with Kraft paper impregnated with VPI 260. After the panel is set in the box, the unit will be
dusted with VPI 250, sealed with impregnated Kraft paper, and the last wooden closure installed.
All precautions should be made to have the enclosure air tight. This preparation should keep the
panel in good condition until it is ready for installation. If inspection is necessary, then open the
box at one end, and after inspection, add a small amount of VPI 250 before resealing.
Field mounted transmitters and controllers shall be enclosed in plastic bags that contain VPI 250.
Bags shall be thoroughly sealed and instrument placed in a protective carton before boxing in
accordance with Section 3.
Pressure gauges, dial thermometers, pressure and temperature switches, and all other small
articles shall be individually wrapped in Kraft paper impregnated with VPI 270 and placed in
protective cartons before boxing in accordance with Section 3.
Level gauges, continuous drainers, etc., shall be protected internally with VPI 250, sealed off
from the atmosphere, and the external surfaces covered with Rust-Ban 339 before packing and
boxing for equipment.
All relief valves and control valves shall have the flanges painted with “Rust-Ban 373”, and the
rest of the unpainted interior and exterior surfaces coated with “Rust-Ban 339”. Flange covers
with gaskets will be installed before shipping.
All relief valves and control valves shall be shipped in totally enclosed wooden boxes that have
been lined with Kraft paper treated with Shell VPI 260.
Protective Products
If any of the protective products mentioned in Sections 4, 5 & 6 are not available, the approval of
OWNER must be obtained before a substitute is used.
19 Marking instructions
All cases, packages and boxes are to be stenciled in Black weatherproof ink on top and
two adjacent sides in clear legible characters. On bundles the markings are to be
embossed on a metal or similar tag and securely strapped on. Paint shall be used on
metal surfaces. Where the surface to be marked is dark, a coat of flat-zinc-white paint
shall be applied and allowed to fully dry before applying the specific marking.
Do not use linen paper or light cardboard tags. Special marks, such as “fragile” or arrows, shall
be in Red. No advertising shall appear on packages.
Shipping marks must appear on all packages, tags, labels and packing list(s).
SHIP TO:
MADE IN:
P.O. NO.:
EQUIPMENT TAG NUMBER:
PACKAGE NO.:
GROSS WEIGHT: kg
NET WEIGHT: kg
DIMENSIONS: (L) x (W) x (H) mm
20. CERTIFICATION
One (1) copy of the packing list and technical data including certification shall be placed
in a sealed waterproof envelope and firmly fastened to the non-working surface of the
equipment in such a fashion that it will not be torn away.
Gas Composition
Component Mol% Pseudocom Gravity Comments
(dry) p
Character
Nitrogen 0.6658 Mol wt
Carbon Dioxide 8.6158
Hydrogen Sulphide 0.0000
Methane 75.9510
Ethane 7.3835
Propane 2.6830
i-Butane 0.5565
n-Butane 0.5167
i-Pentane 0.8149
n-Pentane 0.0398
n-Hexane 0.2782
Benzene 0.0298
n-heptane 0.0298
Toluene 0.0894
n-Octane 0.0398
n-Nonane 0.1590
n-Decane 0.0398
n-Undecane 0.0199
C12+ 2.0870 246 0.85
Total 100.000