HP Duplex Ball Valves 01-P-1-008 Rev 07 - Item1&2

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KHALDA PETROLEUM CO.

Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

SPECIFICATION FOR HIGH-PRESSURE


DUPLEX STAINLESS STEEL
BALL VALVES
01-P-1-008 R7

1/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

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

2/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

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

12 HANDLING, PACKING, STORAGE AND SHIPPING


12.1 Handling .............................................................................................................................. 23
12.2 Packing and shipping .......................................................................................................... 23
12.3 Storage ................................................................................................................................ 23

13 ~ 21 General Requirements………………………………………………………………………………24~40

3/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

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.

For the purpose of this specification:


COMPANY: Khalda Petroleum Company or its appointed representatives.
VENDOR: the company designated on the purchase order form as being the selected
VENDOR of the goods, materials and services.

1.4 Abbreviations

Within this document, the following abbreviations are used:

API - American Petroleum Institute


ASME - American Society of Mechanical Engineers
ASTM - American Society for Testing of Materials
ASNT – American Society of Non-Destructive Testing
BS - British Standard
DN - Diameter nominal (mm)
DPI - Dye reentrant inspection
EN – Euro-norm
IRN - Inspection release note
ISO - International Standards Organization

MOP - Maximum operating pressure

4/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

MPI - Magnetic particle inspection


MSS - Manufacturers Standardization Society
NDE - Non-destructive examination
PR - Performance requirement
PWHT - Post weld heat treatment
SAE - Society of Automotive Engineers
UNS – Unified Numbering System

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.

1.6 Quality Conformance

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.

5/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

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

6/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

3 DESIGN AND OPERATING DATA

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.

3.1 COMPANY Expediting and Inspection


VENDOR, at their own cost, shall supply private office (sole occupation) space for
COMPANY approved third party inspectors. Services shall include, facsimile, international
telephone, email and stationary as a minimum.
The VENDOR shall provide any reasonable assistance to the COMPANY for verification,
documentation or movement of items.
Access for the COMPANY or his appointed representatives to manufacturing facilities at both
the VENDOR and major sub-vendors shall be afforded at all times during the production of
the order up until completion of an acceptable Data Book.

7/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

4 BALL VALVE DESIGN

4.1 General

The component ball valves shall meet the requirements of API6D/ISO14313/ASME


B16.34 except as modified by this Specification.
The VENDOR shall propose a valve that complies with the requirements of the Valve
Data Sheets. Alternative may be proposed by the VENDOR provided with full supporting
design data, in-field maintenance requirements and in-service history.
Actuators and supporting control equipment shall be provided where indicated in
accordance with the actuator specification.
All valves shall have pressure/temperature rating complying with the standard rating tables of
ASME B16.5 and shall be fit for service as shown in the Valve Data Sheets.
Dimensions for face to face, centre to face, end to end and centre to end of valves shall be in
accordance with ASME B16.10 as appropriate.
VENDOR shall furnish drawings and/or specifications to the COMPANY for
comments/approval.
It is understood that the suggestions, recommendations for design, variations and fabrication
changes issued by the COMPANY do not relieve the VENDOR from any responsibilities
concerning the compliance with all requirements of this Specification and/or from the
fulfillment guaranties.
The drawings shall at least contain the following information:

 Material (chemical composition, mechanical strength properties).

 Design, maximum operating and allowable pressures / temperatures.

 Test pressure.

 Dimensions including overall dimensions shown in three planes.

 Only certified equipment to be used in zone 1 (electric) hazardous areas.

 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.

8/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

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

9/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

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.

4.7 Stem, Stem Seal and Drive Train

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.

10/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

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

Penetrations of the valve pressure-retaining boundary shall be avoided except where


otherwise stated in this Specification or on the Valve Data Sheets.
Where penetrations are necessary for valve testing but will not be required in service,
the VENDOR shall make proposals for permanently sealing them and verifying their
integrity if assembled post testing.
Connection to the valve shall be by means of a butt weld or a socket weld connection.
Socket welds shall meet the requirements of ASME B16.34. In addition, socket depths
shall meet the requirements of ASME B16.11 and inserted pipes shall be clear of the
bottom of sockets by approximately 2 mm.
Screwed body penetrations are not permitted.

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.

11/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

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

5.2.1 Valve Body, Bonnet/Top Cover Materials

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.

12/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

5.2.3 Duplex Steel Manufacture

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.

13/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

5.3 Valve Trim


Unless otherwise specified in the Valve Data Sheets, ball valve trim including the ball
and where appropriate, the seat assembly shall be 22% chromium duplex stainless
steel to UNS S31803 as specified in section 5.2. Alternative materials may be offered
by the VENDOR, which shall be subject to approval by the COMPANY. the ball shall be
formed by forging. Cast ball shall not be permitted.

5.4 External Bolting


Bolting and nuts shall be to ASTM A-320 L7 and ASTM A-194 Grade 7 respectively.
Bolting and nuts shall be zinc electroplated and passivated to the requirements of BS
3382 Part 2. VENDOR shall provide certification for bolts and nuts verifying materials
heat treatments and mechanical tests.
5.5 Welding
.

All welding shall be carried-out by qualified welders according to qualified welding


procedure specifications, which have been reviewed and accepted by the COMPANY.
For welded valves, welding procedures, qualifications and testing shall be in
accordance with the reference standards given in API 6D/ISO 14313. All butt weld
qualification tests shall additionally include transverse Charpy V-notch impact tests
taken from the weld metal and heat affected zone according to API 6D/14313. 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.
If valve bodies are cast, then the maximum depth of the repair is limited to 25% depth of
the wall thickness and the Vendor shall submit repair procedures covering castings and
all records including dimensions and NDE records.
Where applicable, welding procedure specifications and qualification for attachment of
pup pieces to the valve body shall be in accordance with 05-2520-01-P-1-030 Field
Welding of Duplex Steel Pipelines to unless otherwise specified by the COMPANY.
For welds in 22% duplex stainless steel, welding procedure qualification tests shall
include a microstructural examination, including ferrite/austenite determination,
according to section 5.2 in the weld metal and heat affected zone (HAZ). The ferrite
content shall be in the range 35 to 55% in the HAZ and 35 to 60% in the weld metal.
Surface Treatment and Coatings
5.6 Trim Surface Treatment
Balls and sealing areas of seats shall be tungsten carbide coated in accordance with a
procedure, which has been accepted by the COMPANY. The coating material shall be
suitable for the Design Life. The vendor shall submit a qualification report for each
material type followed by production and test records for each batch, which shall
include porosity, adhesion, and coating thickness.

14/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

6 NON-DESTRUCTIVE EXAMINATION

6.1 Non-destructive Examination (NDE)

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

15/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

.2 Repair of defects Detected by Non-destructive Examination

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.

Weld repair of discontinuities shall be as follows:


(a) Repair of discontinuities in parent material by welding shall only be permitted for
castings and is not acceptable for forgings. All such repairs shall be carried-out by
qualified welders according to qualified welding procedures, which have been
approved by the COMPANY prior to commencing work. Vendor shall submit
qualified weld procedures.
(b) Repairs penetrating more than 25% through the thickness shall not be permitted.
(c) Records shall be made of all excavations including dimensions and these shall be
made available to the COMPANY.
(d) Excavations for removal of casting defects shall be inspected by DPI for corrosion
resistant alloys prior to weld repair to ensure the complete removal of defect.
(e) Weld repairs shall be subject to NDE as specified in API 6D/ISO 14313 and
COMPANY approved procedures as noted in this specification.
Weld repairs shall not be subject to further repair. Such welds in castings shall result in
rejection of the casting. Such welds joining valve components shall be cut out and re-
welded in accordance with qualified weld procedures
No weld repair is permitted on the ball, stem or other forged components.

16/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

7 PERFORMANCE TESTING

7.1 General

Appropriate safety measures shall be in place for all pressure tests.

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.

7.2 General Test Requirements

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.

Pressure gauges and pressure/temperature recorders shall be calibrated and certified


before tests. The pressure range of the gauges shall not exceed twice the specified test
pressure. All pressure tests to be chart recorded and the following details to be included

 Test Pressure

 Duration

 Temperatures of ambient air and test water shall be recorded.

Valves shall be operated for at least five cycles prior to testing.

Following completion of testing, the valve components shall be thoroughly dried to


remove all traces of water.

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.

17/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

7.3 Hydrostatic Body Test


Hydrostatic Body test shall be performed in accordance with BS EN 12266-Parts 1 and 2.
Stable conditions, with the ball in the half open or fully open (with all areas connected)
condition, shall be achieved for at least 10 minutes prior to commencing the test. All air shall be
vented before the test commences and the valve pressurized to the test pressure.
The hydrostatic test pressure of 1.5 times the pressure rating of the valve and shall be
maintained for a minimum of 1 hour with no visible signs of leakage or pressure drop.

7.4 Hydrostatic Seat Leak Tests

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.

Table 1 Hydrostatic Test Seat Leak Rate

Test Description Criteria


Hydro-static Seat Tightness Test Leakage across the seat shall not be
permitted for the hydrostatic test

Upon completion of this test, the valve shall be depressurized and the test repeated on the
other seat.

7.5 Pneumatic Seat Test - For Gas Service Valves Only

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.

The leakage rates shall be accordance with Table 2.

After completion of leak test, a check is to be carried out to ensure correct alignment of ball and
valve bore.

18/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

Table 2 Gas Leakage Rates

Valve Seat 1 barg 5.5 barg


Type
Metal to Metal BS EN 12266 BS EN12266
Rate B Rate B

For soft seated ball valves the acceptable gas leakage rate shall be in accordance with
BS EN 12266 Rate A.

7.6 Operational Torque Test

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%.

Alternative means of torque measurement, such as measurement of actuator hydraulic


pressure, may be proposed by the VENDOR but shall be subject to acceptance by
COMPANY.

The VENDOR may, at its discretion, opt to conduct a torque test at the end of each seat
test.

7.7 Integrated Performance Testing

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.

19/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

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

9.1 Painting & 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.

Color = Black (Coal Tar type Paint)

Coating of Above Ground Valves

Shall be with a 4-coat system to include:


 Surface preparation by blasting to SA 2½ and solvent cleaning of any contaminants
shall be undertaken
 Surface primer
 Corrosion resistant layer
 Protective layer for above
 Cosmetic layer / Transit protection
 The final DFT shall be a minimum of 350 microns.
 The paint system shall be suitable for a 25-year design life in the Egyptian desert
environment.
 Color = Sand, BS 4800 08-C-35, Munsell 10 YR 7/6

20/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

10 QUALITY ASSURANCE AND CONTROL

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.

10.2 Inspection and Test Plan

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 inspection and test plan shall include:

- The characteristics to be inspected at each inspection point, the procedures, the


responsible person and acceptance criteria to be used. The procedure shall be
provided to the COMPANY, as requested.
- Copies of specific forms used by the VENDOR to record the results of each
inspection.

10.3 Special Process Procedures

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.

The VENDOR shall:

- Establish means to ensure special processes are accomplished under controlled


conditions by qualified personnel using acceptable materials, procedures and
equipment as required by specifications. Any special processes shall be subject to
review and acceptance by COMPANY prior to commencement of the work.
- Establish and maintain documented evidence of control of special processes.
- Maintain evidence of qualification status of personnel, processes or equipment
according to the requirements of pertinent codes and standards.

10.4 Quality Records

The VENDOR shall maintain quality records as documentary evidence of compliance


with quality requirements. Quality review shall be available to the COMPANY for
analysis and review.
Quality records may include: item identification by reference to drawing and revision
number, acceptance criteria, specific inspections performed and results obtained (if
measurements are not required, include in the record basis of acceptance), date of
inspection, identification of inspector, data recorder charts, qualification of material
personnel, procedures and equipment.

21/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

10.5 Final Inspection


The VENDOR shall inspect the final item to ensure compliance with contract requirements.
A check shall be made of all inspection records to verify that items were inspected at all points
shown in the inspection plan. These records shall be complete and available to 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.

22/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

12 HANDLING, PACKING, STORAGE AND SHIPPING

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).

Whenever possible, valve-lifting padeyes shall be used for handling.

All other handling of valves shall be carried out using broad non-metallic belt slings.

12.2 Packing and shipping

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.

23/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

13 DOCUMENTATION REQUIREMENT

13.1 DOCUMENT MANAGEMENT SYSTEM


13.1.1 Document Formats
Following to the requirements raised in point No.10.1 above, the VENDOR shall adopt a
standard format for all VENDOR documents and a standard title block for all project
drawings, which shall be mutually agreed with the OWNER’S REPRESENTATIVE
/Third party inspection (TPI). Documents sizes shall conform to ISO standards except
that sizes greater than A1 shall not be used.
All documents shall be written in the English language or shall be certified translations.
All documents shall have front sheets in an OWNER’S REPRESENTATIVE /Third party
inspection (TPI) approved format (see Appendix A).
Dimensions and all other units of measurement shall be in accordance with the SI
system, except for pipe diameter, which may be expressed in inches.
Each page of a document shall be numbered in a manner that indicates the total
number of pages within the document (e.g. 1 of 8, 2 of 8, etc). Each page shall also
indicate the document number and the current revision.
All documents shall be submitted in a sufficiently high quality to allow scanning without
loss of information.

13.2 Documentation Submission


13.2.1 Major Purchase Orders
All major purchase orders will contain a Supplier Documents Required List (SDRL)
requirement in the form of a main SDRL applicable for the goods to be supplied (item
14 follows). VENDOR’s shall submit documents in accordance with the listing contained
within the applicable purchase order SDRL. The applicable purchase order SDRL will
state the timing requirements for VENDOR documentation submissions both prior to
production start-up and during production.
Documents shall be submitted as native format (e.g. MS Word) or as Adobe Acrobat
pdf files.
13.2.2 Other Purchase Orders
For purchase orders where a SDRL is not required, copies of the following documents
shall be submitted for OWNER’S REPRESENTATIVE /Third party inspection (TPI)
review:
 General arrangement drawings for all non-standard or specialist items
 Manufacturing schedules covering the VENDOR and all SUB-VENDOR
activities
 Un-priced sub-orders
Prior to submission all documents produced by or on behalf of the VENDOR shall be
subject to the VENDOR's internal review, to verify compliance with the Purchase Order
requirements, statutory requirements and good engineering practice. The VENDOR
shall ensure that prior to submission to OWNER’S REPRESENTATIVE /Third party
inspection (TPI) their authorized personnel approve all documents for issue.

13.3 Documentation Review


The OWNER’S REPRESENTATIVE /Third party inspection (TPI) will review all
documentation submissions. Comments will be returned the VENDOR on Comments
Sheets where practical, otherwise documents will be hand marked with comments. All
documents submitted to the OWNER’S REPRESENTATIVE /Third Party Inspection
(TPI) for review, are subject to a 10 working day review cycle.
Where possible the OWNER’S REPRESENTATIVE /Third party inspection (TPI) will
return comments in advance of the ten working day review cycle.

24/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

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.

25/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

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.

26/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

14. Supplier documents required list (SDRL)


Code Number Document With For To Be Submission
Quotation Approval Verified Time
Calculations C01 Stress Analysis Calculations
C02 Pressure Vessel Code Calculations
C03 Foundation/Support Loading Calculations
C04 Design Calculations A4
C05 Structural Steel Calculation
C06 Unbalanced Force Calculations
C07 System Head Loss Calculations
C08 Lateral Critical speed Calculations
C09 Tensional Critical Speed Calculations
C10 Flow Element Calculations
C11 Wind Load Calculations
C12 Conveyor CEMA Calculations
C13 Non-Code Bin, Hopper, Silo Design Calculations
C14 Process Calculations
C15 Hydraulic Calculations
C16 Bearing Life Calculations
C17 HVAC Calculations
C18 Barge Transportation Calculations
C19 Hydrostatic Testing Calculation (c/w End Loading) A4
C20 Pcm/CE/PREn Calculations (including Weld Metal) A4
C21 Allowable Force and Moments for Compressor
Flanges
C22 Pressure Drop Curves for Inlet Air Filter System
C23 Radio Propagation study
C24 Fiber Optic Link Calculation
C25 Satellite Link Budget Calculation
C26 Passive Cooling Cabin Load Calculation
C27 Solar Power System Load Calculation
C28 Tower Calculation
C29 Seat Spring Force Calculation A4
C30 Maximum Force Required at Handwheel or Lever A4
C31 Design Minimum Wall Thickness A4
Drawings
D01 General Arrangement Drawings for Manufacture A4
D02 Detailed Drawings A4
D03 Outline Drawings Yes
D04 Exploded View Drawings
D05 Floor Plan Drawings
D06 Isometrics
D07 Piping and Instrumentation Diagrams
D08 Logic Diagrams
D09 Electrical/Electronic Schematics
D10 One Line Electrical Diagrams
D11 Electrical Interconnection Diagrams
D12 Electrical Internal Connection Diagrams
D13 Electrical Schematics and Wiring Diagrams
D14 HVAC Schematic and Wiring Diagrams
D15 Support/Foundation Details
D16 Manufacturing / Fabrication Drawings
D17 Completed Data Sheets A4
D18 As-Built Drawings D2
D19 Telecommunications Internal Connecting Diagrams
D20 Telecommunications Interconnection Diagram

LEGEND Document Types: Submission Time Code


C - Calculations D - Drawings E – Equipment A-No. Weeks after P.O Issue Date
M - Manuals P - Procedures Q - Quality Assurance D-No Weeks prior to delivery (OD=On Del)

R - Results S - Schedule T - Technical Reports T-No. Weeks after Completion of Testing


Z – Other S-No. Weeks after Shipment

27/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

Code Number Document With For To Be Submission


Quotation Review Verified Time
Equipment
E01 Electrical Relay Characteristics, Ratings and
Instructions
E02 Current, Potential and Power Transformer Curves
E03 Motor Performance Curves
E04 Electrical Fuse/Circuit Breaker Characteristic Curves and
Instructions
E05 Motor Heating and Safe Locked Rotor Time Curves
E06 Motor Curve for Torque and Current versus Speed
E07 Equipment Performance Curves and Data

Manuals M01 Operating Manuals D2


M02 Maintenance Manuals D2

Procedures P01 Manufacturing/Fabrication Procedure Specification


P02 Weld Procedures, Specifications A4
P03 Weld Repair Procedure Specifications A4
P04 NDT Procedures A4
P05 Long Term Testing Procedures including SSC and HIC
Testing
P06 Hydrostatic Test Procedures A4
P07 Electrical/Magnetism Test Procedures
P08 Painting/Coating Procedures – including ball seats A4
P09 Packing and Shipping Procedures A4
P10 Installation Procedures
P11 Heat Treatment Procedures A4
P12 Coating Test Procedures A4
P13 Dimensional Control Procedure
P14 Weighing Procedure
P15 Handling Procedures
P16 Corrosion Protection Procedure (including Inspection
Procedure)
P17 Administration Procedures
P18 Safety Procedures
P19 Storage Procedures
P20 Batching Procedures
P21 Coating Repair Procedures A4
P22 Commissioning Procedure
P23 Weld Numbering Procedure
P24 Manufacturing Qualification Procedure
P25 Acceptance Test Procedure
P26 Weldability Test Procedure
P27 Bending Test Procedure
P28 Marking Procedure A4
P29 Coating Inspection Procedure A4
P30 Centerline Segregation Evaluation Procedure
P31 Mechanical Test Procedure
P32 Hardness Test Procedure
P33 Material Control Procedure
P34 Casting Weld Repairs A4
LEGEND Document Types: Submission Time Code
C - Calculations D - Drawings E - Equipment A-No. Weeks after Contract Issue Date
M - Manuals P - Procedures Q - Quality Assurance D-No Weeks prior to delivery (OD=On Del)

R - Results S - Schedule T - Technical Reports T-No. Weeks after Completion of Testing


Z - Other S-No. Weeks after Shipment

28/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

Code Number Document With For To Be Submission


Quotation Review Verified Time
Procedures
(cont’d) P34 Visual Inspection A4
P35 Actuator/Valve Performance Test Procedure A4
P36 Compressor Lateral Critical Speed Analysis
P37 Turbine Lateral Critical Speed Analysis
P38 Pump and Engine Torsional Critical Speed Analysis
P39 Coupling Balance Procedure
P40 Anti-Surge and Performance Controller System
P41 Factory Crude Burning Engine Mechanical Run Test
P42 Factory Crude Burning Engine Performance Test
P43 Factory Pump Mechanical Run Test
P44 Field Final Acceptance Test
P45 Field Inlet and Exhaust Pressure Loss Test
P46 Air Emissions Testing
P47
P48

Quality Q01 Quality Plan Yes A2


Assurance Q02 Inspection and Test Plan Yes A2
Q03 Pipe Tracking Procedure
Q04 Quality Control Procedures
Q05 Quality Assurance Procedures
Q06 Material Tracking Procedure A4

Results R01 Manufacturing Procedure Qualification Test Results


R02 Weld Procedure Qualification Test Results T2
R03 Weld Repair Procedure Qualification Test Results T2
R04 Welder Approval Certificates/Identification T2
R05 NDT Operators Qualification Certificates T2
R06 Long Term Test Results including SSC and HIC Test
R07 Chemical Analysis Results (including Grain Size and T2
Weldments Chemistry)
R08 Mechanical Test Results T2
R09 Hydrostatic Test Results T2
R10 Letter of Conformity T2
R11 Electrical/Magnetism Test Reports
R12 Heat Treating Records T2
R13 Release List
R14 Cast Record
R15 Dimensional Control Reports/Dimension Inspection T2
Reports
R16 NDT Reports T2
R17 Impulse Voltage Test Record
R18 Electrical Equipment Heat Run Test Records
R19 Vibration Test Report
R20 Lifting Equipment Test Certificates
R21 HVAC System Testing, Adjusting and Balance Report
R21 Test Data and/or Historical Data Seat Material – A4
Demonstrating No Galling for Selected Materials
LEGEND Document Types: Submission Time Code
C - Calculations D - Drawings E - Equipment A-No. Weeks after Contract Issue Date
M - Manuals P - Procedures Q - Quality Assurance D-No Weeks prior to delivery (OD=On Del)
T-No. Weeks after Completion of Testing
S-No. Weeks after Shipment
T-No. Weeks after Completion of Testing
S-No. Weeks after Shipment

29/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

Code Number Document With For To Be Submission


Quotation Review Verified Time
Results
(Cont’d) R22 Mill Certificates T2
R23 Hardness Test Results T2
R24 Weekly Inspection Reports T2
R25 Corrosion Test Results
R26 Coating Test Results T2
R27 Material Certificates for Supplier’s/Contractor’s T2
Materials
R28 Visual Inspection Reports T2
R29 Weighing Reports T2
R30 Calibration Certificates T
R31 Packing for Shipment Report T2
R32 Administration Procedures
R33 Name Plate Rubbing T2
R34 Material Tracking Record T2
R35 Pipe Tracking Record T2
R36 Acceptance Test Report T
R37 Release Certificate T
R38 Weldability Test Results
R39 Bending Test Results
R40 Centerline Segregation Evaluation Report
R41 Actuator Performance Test Results T2
R42 Valve Performance test Results T2
R43 Data Book S2
R44 Campbell and Goodman Diagram
R45 Compressor Lateral Critical Speed Analysis
R46 Engine Lateral Critical Speed Analysis
R47 Pump and Engine Torsional Critical Speed Analysis
R48 Engine Performance Curves
R49 Field Final Acceptance Test Report
R50 Air Emissions Test Report
R51 Data Book Index A4
R52

Schedules S01 Supplier Document Schedule A2


S02 Manufacturing/Delivery Schedule A2
S03 Material List and Schedule A2
S04 Weight Schedule
S05 Recommended Spares (Start Up and Long Term) D2
S06 Lubrication Charts D2
S07 Instrumentation Schedule
S08 Cable Schedule
S09 Junction Box Schedule
S10 Equipment Schedule

LEGEND Document Types: Submission Time Code


C - Calculations D - Drawings E - Equipment A-No. Weeks after Contract Issue Date
M - Manuals P - Procedures Q - Quality Assurance D-No Weeks prior to delivery (OD=On Del)

R - Results S - Schedule T - Technical Reports T-No. Weeks after Completion of Testing


Z - Other S-No. Weeks after Shipment

30/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

Code Number Document With For To Be Submission


Quotation Review Verified Time
Technical
Reports T01 Technical Specifications
T02 Standard Specifications Relating to Equipment etc
T03 Design Reports/Technical Notes
T04 Control Panel Installation Design

Others Z01 Catalogues


Z02 Reference Lists
Z03 Sub Orders un-priced A4
Z04 Sub Order Schedule A4
Z05 List Major Sub Orders and the Bidders List A4
Z06 Material/Procurement Specification
Z07 Weldability Data
Z08 Historical Data
Z09 Safety Policy Statement
Z10 Comprehensive Description of Control Systems
Z11 Purchaser’s Personnel Training Programme
Z12 Ready for Start Up Notice

LEGEND Document Types: Submission Time Code


C - Calculations D - Drawings E - Equipment A-No. Weeks after Contract Issue Date
M - Manuals P - Procedures Q - Quality Assurance D-No Weeks prior to delivery (OD=On Del)

R - Results S - Schedule T - Technical Reports T-No. Weeks after Completion of Testing


Z - Other S-No. Weeks after Shipment

Document Review Codes A1 Accepted without comment


A2 Accepted with comment – manufacture B Rejected – resubmission in acceptable
may proceed providing comments are format is required.
complied with.
C Certified Document Review D Information Only

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.

31/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

15. Protection of valves and other goods during Shipment

15.1 General scope:


It is intended to serve as a minimum requirement guide and will depend on use of
VENDOR’S judgment to determine if physical characteristics of items being packed will
require more than these minimum standards to ensure safe arrival at their destination.
When portions of these instructions are not applicable, the best commercial export
packing methods to attain comparable protection shall be used. In all cases, valves will
be prepared for shipment to withstand multiple handling, outside storage, exposure to
rain, dust and salt spray.
If the standard export packing will provide equal or better protection at a lesser cost,
this information should be brought to the attention of the OWNER. If an area of doubt
should arise, the OWNER shall be contacted.
If VENDOR deems that a product is available on the market that is the equivalent of
any product quoted within this specification, they must seek approval from OWNER for
its use and only when approved may it be used for the requirement.

PACKAGING STANDARDS AND FUMIGATION.


The packing standards and fumigation, as outlined in these instructions, are for all
shipments.
Egypt has published requirements adopting the International Standards for
st
Phytosanitary Measures (ISPM 15). From 1 October 2005, all shipments must comply
with the packaging requirements of ISPM 15.

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.

15.2 Fumigation Requirements for Egypt


Fumigation is required for wooden cargo and/or cargo in wooden boxes. Fumigation is
to be conducted before loading and each item or parcel must clearly show written proof
of this in the form of a certificate.

32/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

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

SAMPLE MARK Country Code


Unique country approved treatment company
registration number. Leading zeros are optional if
printing space is limited

IPPC logo Treatment code


(as appropriate)
15.4 Packing
Valves and other goods should be packed to withstand rough handling, extreme heat
and high humidity and packing boxes should be waterproofed. All containers entering
into Egypt should be treated. If wooden products or wooden packaging as shipped without
fumigation treatment then Egyptian customs will seize cargo and arrange fumigation for
consignee's account.

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

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

16 Packing Methods and Prohibited Materials

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.

(a) To 140 kg or 300 lbs


Box shall be made of a minimum of 2.5 cm (1”) nominal lumber or 1 cm (3/8”) plywood
sheathing, 5.1 x 10.2 cm (2”x4”) nominal skids, and 2.5 x 10.2 cm (1”x4”) frames with
completely cleated ends. All boxes over 22.6 kg (50 lbs) to be skidded.

(b) 140 to 450 kg, 300 to 1000 lbs


Box shall be made of a minimum 2.5 cm (1”) nominal lumber, or 1.3 cm (1/2”) plywood
sheathing with 5.1 cm (2”) nominal decking and 5.1 x 10.2 cm (2”x4”) nominal skids.
Box to have cleated ends, with 5.1 x 10.2 cm (2”x4”) or 5.1 x 15.2 cm (2”x6”) battens.
34/40 Specification for HP Duplex Ball Valves
01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

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).

16.2 Open Crates Open crates are not allowed.

35/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES


5
17. PROTECTION METHODS

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:

(a) Esso Rust-Ban 373 for hard surface protection.

(b) Esso Rust-Ban 394 for soft surface protection.

(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.

36/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

17.1 Rust preventive method

17.1.1 Shell Company VPI

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:

(a) VPI-270 = 1 gram per 15 cubic inches.

(b) VPI-250 = 3 grams per cubic foot.

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:

Rust Ban appearance Thickness Life Coverage Removal


373 Hard Dark 0.22’’ 1 year outside 350 sqft/gal Solvent, film alkali
2 years inside or emulsion

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

Rust-ban Refining Co. SHELL Oil Company EF Houghton &Co


373 Petrotect IX Ensis Fluid 264 Cosmoline 1058
394 Petrotect 2 Ensis Fluid 210 Cosmoline 1059
339 Petrotect 3 Ensis Oil 30 Cosmoline 1049

37/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

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.

Relief Valve & Control Valves

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.

38/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

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.

Weights must be shown in kilograms; dimensions in centimeters. (Imperial weights and


dimensions may be shown but they must not be more than half the size of metric figures).

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.

39/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7
KHALDA PETROLEUM CO.
Gas Development Projects

GENERAL SPECIFICATION FOR HIGH-PRESSURE DUPLEX BALL VALVES

21 Applied Gas composition

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

40/40 Specification for HP Duplex Ball Valves


01-P-1-008 R7

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