MM-ZTK-1A-ONEP-PIP-SPE-5003 Rev C1_Spec for Gate Valves.pdf

ZAWTIKA DEVELOPMENT PROJECT PHASE 1A

EPCIC OF ZAWTIKA ONSHORE PIPELINE

CONTRACT NO. : IMO-EMP-CT-10-0018

SPECIFICATION FOR GATE VALVES

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B1 07-Nov-11 TL Issued for Approval ZLH SB

Issued for Review A2 05-0ct-11 TL ZLH SB

14-Sep-11 Issued for Review A1 TL ZLH SB

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DATE DESCRIPTIONREV BY CPP COMPANY APPROVAL APPROVAL

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WL SB

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CHECK CHECK

REVISION CODE: A =Issued for Review (IFR); B =Issued for Approval (IFA); C =Approved for Construction (AFC)

TOTAL OR PARTIAL AND I OR UTILIZATION OF THIS DOCUMENT ARE FORBIDDEN WITHOUT PRIOR WRITIEN AUTHORIZATION OF THE OWNER

• PTTEP INTERNATIONAL LIMITED

ZAWTIKA DEVELOPMENT PROJECT PHASE 1A EPCIC OF ZAWTIKA ONSHORE PIPELINE

REV CLASS MM-ZTK-1A-ONEP-PIP-SPE-5003 CPPC1 1

PTTEP International Limited Page 2/12

Zawtika Development Project Phase 1A Document : MM-ZTK-1A-ONEP-PIP-SPE-5003

EPCIC of Zawtika Onshore Pipeline Revision : C1 Date : 21-Nov-11

Table of Contents

1.0 SCOPE ......................................................................................................................................................... 3

2.0 PRECEDENCE ............................................................................................................................................ 3

3.0 REFERENCES ............................................................................................................................................. 3

3.1 PROJECT SPECIFICATIONS AND DATA SHEETS ................................................................................................................. 3 3.2 CODE & STANDARDS ................................................................................................................................................. 3

4.0 DEFINITIONS ............................................................................................................................................... 4

5.0 SITE AND ENVIRONMENTAL CONDITIONS ........................................................................................... 5

6.0 SPECIFICATIONS ....................................................................................................................................... 5

6.1 DESIGN REQUIREMENTS ............................................................................................................................................. 5 6.2 MATERIAL ............................................................................................................................................................... 7 6.3 INSPECTION AND TESTS .............................................................................................................................................. 7 6.4 PAINTING AND EXTERNAL PROTECTION ......................................................................................................................... 8 6.5 TAGGING AND IDENTIFICATION .................................................................................................................................... 8 6.6 DOCUMENTS TO BE SUBMITTED ................................................................................................................................... 9

6.6.1 Bidding documents ....................................................................................................................................... 9 6.6.2 Documents to be Submitted after Ordering ............................................................................................... 10 6.6.3 Documents to be Submitted during Delivery .............................................................................................. 10

6.7 PACKING AND SHIPPING ........................................................................................................................................... 10 6.8 TECHNICAL SERVICES ............................................................................................................................................... 11

6.8.1 Technical Support ....................................................................................................................................... 11 6.8.2 Training ....................................................................................................................................................... 11

6.9 ACCEPTANCE .......................................................................................................................................................... 11 6.9.1 Factory Acceptance ..................................................................................................................................... 11 6.9.2 Acceptance after AOG ................................................................................................................................ 11 6.9.3 Intermediate Acceptance ............................................................................................................................ 12 6.9.4 Final Acceptance ......................................................................................................................................... 12

6.10 AFTER‐SALE SERVICES .............................................................................................................................................. 12 6.11 GUARANTEE AND WARRANTY ................................................................................................................................... 12




1.0 SCOPE

This Specification defines the minimum requirements for the design, materials, fabrication, inspection and testing of gate valves for use on the Zawtika Onshore Pipeline. All material shall meet the requirements of this specification and shall satisfy the requirements of NACE standard, MR0175, as applicable for the desired service conditions.

2.0 PRECEDENCE

Any case of apparent conflict between the requirements of this Specification, other referenced documents and, Codes and Standards shall be notified to the CONTRACTOR. Unless otherwise agreed, the following descending order of precedence shall apply:

1st Government Laws, Rules and Regulation

2nd Purchase Order/ Service Order/ Contract Documents 3rd This Specification

4th Other Internationally recognised Codes or Standards as appropriate

3.0 REFERENCES

The following documents, latest editions, are referred to in this Specification. 3.1 Project Specifications And Data Sheets

MM-ZTK-1A-ONEP-PIP-SPE-5005 Piping Material Specifications (Line Classes)

MM-ZTK-1A-ONEP-PIP-LIS-5002 Valve Schedule

MM-ZTK-1A-ONEP-PIP-DTS-5006 Data Sheet for Gate Valves

MM-ZTK-1A-ONEP-CPA-SPE-5009 Painting for Onshore structures and facilities

3.2 Code & Standards ASME B16.5 Steel Pipe Flanges and Flanged Fittings

ASME B16.34 Steel Valves

ASME Section VIII Div. 1 Boiler and Pressure Vessel Code – Rules for Construction of Pressure Vessels

API 6D

Specification for Pipeline Valves (Plug, Gate,

Check and Ball Valves)

API 6FA Specification for Fire Test for Valves

ASTM A105 Specification for Forgings, Carbon Steel for Piping Components




ASTM A216 Specification for Steel Castings, Carbon, Suitable for Fusion Welding for High Temperature Service

ASTM A234 Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and Elevated Temperatures

ASTM A350 Specification for Forgings, Carbon and Low Alloy Steel, Requiring Notch Toughness Testing for Piping Components

ASTM A352 Specification for Steel Castings, Ferritic and Martensitic, for Pressure Containing Parts, Suitable for Low-Temperature Service

MSS-SP-53

Quality Standard for Steel Casting and Forgings for Valves, Flanges and Fittings and Other Piping Components – Magnetic Particle Examination Method

NACE MR 0175 Material Requirements – Sulphide Stress Cracking Resistance of Metallic Materials for Oil Field Equipment

BS EN 10204 Metallic Products – Type of Inspection Documents

ISO 9001:2000 Quality Management Systems - Requirements

4.0 DEFINITIONS

Throughout this Specification, the following definitions shall apply:

COMPANY: PTTEP International Limited

COMPANY’S REPRESENTATIVE: It means an individual or company employed by PTTEP International Limited to act on their behalf

CONTRACTOR: China Petroleum Pipeline Bureau (CPP)

PROJECT: ZAWTIKA DEVELOPMENT PROJECT,PHASE 1A EPCIC OF ZAWTIKA ONSHORE PIPELINE

DELIVERIES: Complete set of equipment/ materials to the CONTRACTOR as required by the technical specification;

SUB-CONTRACTOR The company or manufacturer responsible for designing and manufacturing the equipment/ materials as stipulated in the subcontract

VENDOR: It means any manufacturer, supplier, VENDOR or fabricator of DELIVERIES

“must”: It signifies a legal or statutory requirement

“shall” It signifies a requirement made mandatory by this specification

“may” It signifies a feature, which is discretionary in the context in which it is applied

“will” It signifies a feature which the VENDOR may assume to be already present.




5.0 SITE AND ENVIRONMENTAL CONDITIONS

The main Climate data are shown in Tables 5.1

Table 5.1-Climate data

Location Range of month Jan-Mar Apr-Jun Aug-Sep Oct-Dec

Aver. max. air temperature1) (℃) 30 31 30 30 Aver. min. air temperature1) (℃) 22 25 25 25

Atmospheric Pressure (kPa) 101.1 100.7 100.6 101.1 Rainfall (% of time) 5 10 25 10

Rainfall intensity (mm) 42 750 1662 382 Relative humidity (%) 75 80 85 78

Duration of sunshine (hours) 795 483 337 581

6.0 SPECIFICATIONS

6.1 Design Requirements

Valve design shall meet the requirements of API Specification 6D and shall be suitable for the service conditions indicated on the Valve Datasheet. The valve body and other pressure containing parts shall be designed in compliance with ASME Section VIII, Division 1. The corrosion allowance indicated on the Valve Datasheet shall be considered in the design; however, the minimum wall thickness shall not be less than the minimum requirement of ASME B16.34.

The valves shall be outside stem and yoke, non-rising stem, parallel/conduit or wedge type gate design, however this specification may be utilised for alternate designs when required by the Purchase Documents. The cover shall be bolted to the body. Screwed connections are not acceptable. Valve seats shall be with primary metal to metal contact. The gate and metal seat ring assembly shall be part matched by lapping. Soft seals, if used for drip tight sealing, shall be encased in a suitably designed groove in such a manner that they cannot be removed from the seat ring, and such that no extrusion occurs during operation at maximum differential pressure. The seat rings shall be designed to ensure sealing, at low, as well as high differential pressures. The valve design shall avoid bimetallic corrosion between carbon steel and high alloy components used in the assembly. Accordingly, suitable insulation shall be provided as required. Valves shall be designed to withstand a sustained internal vacuum of at least 1 (one) millibar in both open and closed positions. Valve design shall provide for the repair of gland packing under full line pressure. Valve ends shall be flanged, as indicated on the Valve Datasheet. Flanges of the flanged end cast body valves shall be integrally cast with the body of the valve. Face to




face dimensions shall conform to API 6D. Flanged ends shall have dimensions as per ASME B 16.5. Flange faces shall be either raised face or ring type joint, as indicated on the Valve Datasheet. For raised face flanges, the face finish shall be serrated or smooth as indicated on the Valve Datasheet. Smooth finish shall be 125 to 250 AARH. The valve stem shall be capable of withstanding the maximum operating torque required to operate the valve against the maximum differential pressure as per the appropriate class. The combined stress shall not exceed the maximum allowable stresses specified in ASME Section VIII, Division 1. The design shall take into account a safety factor of 1.5 based on the maximum output torque of the operating mechanism. Valve stem shall have anti-blowout feature with antistatic device. Repair by welding is not permitted for forged body valves. However, repair by welding as per ASME B 16.34 is permitted for cast body valves. Repair shall be carried out before any heat treatment of the casting is done. The repair Welding Procedure Qualification shall include impact tests and hardness tests meeting the requirements of Paragraph 7.2 of this specification and shall be established in such a manner that the requirements of NACE MR 0175 are met, without the necessity of post weld heat treatment. When specified on the Valve Datasheet, valves shall have locking devices to lock the valve either in the fully open (LO), or fully closed (LC), position. When specified on the Valve Datasheet, gate valves shall be “fire safe” in accordance with API 6FA, for which qualifying certificates, covering the range of items offered, shall be supplied by the Manufacturer. All valves over NPS 6 size shall be equipped with lifting lugs. Tapped holes and eye bolts shall not be used for lifting lugs. Operating Devices:

(a) Valves of NPS 4, and below shall be manually operated. Valves of NPS 6, and

above, shall be gear operated. Gear operators shall be sized such that their output torque is at least 1.5 times the maximum operating torque of the Valve. The Valve design shall be such, that damage due to malfunctioning of the Operator, or its controls, will only occur in the gear train or power cylinder. Damaged parts should be able to be replaced without the Valve cover being removed.

(b) The diameter of the hand wheel for manually operated Valves shall be such that under the maximum differential pressure, the torque required to operate the Valve does not exceed 350 Nm. The Manufacturer shall also indicate the number of turns of the hand wheel required for operating the Valve from the fully open to fully closed position.

(c) The direction of operation of the hand wheel shall be in a clock-wise direction for closing the Valves. Hand wheels shall not have protruding spokes.

(d) Gear operators, where provided, shall have a self-locking provision and shall be fully encased in a water proof/splash proof enclosure (IP65) and shall be filled with suitable grease.




6.2 Material

Materials for major components shall be as indicated on the Gate Valve Datasheet. Other components shall be as per Manufacturers standard, which shall be subjected for approval by the CONTRACTOR. For sour service, all material in contact with the process fluid shall meet the requirements of NACE MR 0175, in particular material chemical composition, fracture toughness and HIC testing.

The acceptable materials for the valve body are carbon steel to grades ASTM A105N, ASTM A216 Gr. WCB / WCC, ASTM A234 Gr. WPB, ASTM A350 Gr. LF2, or ASTM A352 Gr. LCB / LCC. Materials for the disc / body seats shall be ASTM A182 Gr. F316(L), Body material with ENP coating or ASTM A182 Gr. F316(L) + Stellite. The stem shall be of ASTM A182 Gr. F316L. Reference shall be made to the Valve Datasheets for materials of construction of other parts. Carbon steel used in the manufacture of valves shall be fully killed. For all pressure containing parts of the valve, a full thickness cross section shall be taken test per heat of base metal, for the hardness test. The maximum hardness shall not exceed 248 HV10. All carbon steel castings and forgings shall be furnished either in the normalised, normalised & tempered, or quenched & tempered condition. All heat treatment shall comply with the requirements of NACE Standard MR0175. Seal material shall be suitable for the service conditions. Acceptable seal materials are Viton GF or HNBR. Viton A shall not be used. Packing material shall be inhibited Grafoil or equivalent.

6.3 Inspection and Tests

The VENDOR shall to perform all inspection and testing as per the requirements of this Specification and the relevant codes, at his Works, prior to shipment. Such inspection and testing shall include, but not be limited to, the following:

(e) Visual Inspection (f) Dimensional checks on all valves shall be carried out as per the drawings approved

by the CONTRACTOR.

(g) Chemical composition and mechanical properties, including hardness, shall be checked as per the relevant material standards and this specification, for each heat of steel used.

(h) Non Destructive Examination

(i) Non-destructive examination of individual valve materials and components consisting of, but not limited to, castings, forgings, and assembly welds, shall be carried out by the VENDOR.




(j) Body castings of the valves shall be radiographically examined on 100% of the surface of critical areas as per ASME B 16.34. Procedures and acceptance criteria shall be as per ASME B16.34. All castings shall be subject to wet magnetic particle inspection on 100% of the internal surfaces. Method and acceptance shall comply with MSS-SP-53.

(k) All valves with forged bodies shall be ultrasonically examined in critical areas in accordance with the procedures and acceptance standards of Annex-E of ASME B16.34. All forgings shall be subject to wet magnetic particle inspection on 100% of the forged surfaces. Method and acceptance shall comply with MSS-SP-53.

(l) All valves shall be tested in compliance with the requirements of API 6D. During pressure testing, valves shall not have sealant lines and other cavities filled with sealant, grease, or other foreign material. The drain, vent, and sealant lines shall be either included in the hydrostatic shell test, or tested independently. No leakage is permissible during hydrostatic testing.

(m) A supplementary air seat test as per API 6D shall be carried out for all valves.

(n) Valves shall be subjected to an operational torque test, in accordance with the requirements of API Spec. 6D, under a hydraulic pressure equal to the maximum differential pressure corresponding to the valve rating. For manually operated valves, testing shall confirm that the torque required to operate the valve does not exceed 250 Nm.

The CONTRACTOR also reserves the right to witness tests as indicated above at the VENDOR 's works, prior to shipment. The VENDOR shall give reasonable access and facilities required for inspection to the CONTRACTOR 's Inspector. The CONTRACTOR reserves the right to require additional testing, at any time, to confirm or further investigate a suspected fault. All costs incurred shall be for the VENDOR 's account. In no case shall any action of the CONTRACTOR, or his Inspector, relieve the VENDOR of his responsibility for material, design, quality, or operation of the valves. Inspection and tests performed/witnessed by the CONTRACTOR’s Inspector shall in no way relieve the VENDOR of his obligation to perform the required inspection and tests. The CONTRACTOR may, at his discretion, appoint a Third Party Inspection Agency to carry out inspection on behalf of, or together with, the CONTRACTOR’s Inspector.

6.4 Painting and External Protection

All external surfaces of valves, pups, and stem extensions shall be abrasive blasted to SSPC SP-6 to remove all scale, rust, oil, and foreign matter. Complete units shall be painted in accordance with Specification MM-ZTK-1A-ONEP-CPA-SPE-5009, Painting onshore structures and equipment.

VENDOR shall provide adequate external protection against corrosion from salt-laden atmosphere in summer and winter for all valves and actuators. This applies to all external moving parts and openings, the valve bore and weld/flange ends.

6.5 Tagging and Identification




A corrosion-resistant nameplate shall be permanently fixed to all valves supplied under this contract. Such information shall include all marking required by API 6D plus the following:

− Valve Contract

− Valve Serial Number

− Valve Tag Number

− Valve Manufacturer's name and date of manufacture

− Valve Model Number (or catalogue number where applicable)

− Service

− Port Size (or inner valve size if different)

− Nominal Valve Size

− Rating

− Trim Material

− Body Material

− Hydrostatic Test Pressure

− Weight of Valve

− All dimensions, except weight in Metric units, valve sizes, design pressures (max. /min.) and design temperatures (max./min.) in English units

6.6 Documents to be Submitted

All documents, drawings and calculation formulas to be submitted shall use the international system of units. 6.6.1 Bidding documents

During bidding, the Vendor shall provide the following documents to the CONTRACTOR:

− Document of response to the specification.

− Test acceptance outline

− List of achievements and tracking report

− Relevant technical information of valves, e.g., samples, drawings and calculation sheets etc.

− Confirmation charts of structures

− Manufacturing/inspection time plan

− The technical standards related to design, manufacturing, test and inspection, and specific inspection and test indexes

− The rated torque for opening and closing a valve under total differential pressure




− Procedures of chemical nickel plating, subcontractor performance, and testing methods etc.

− The commitment to valve quality, reliability, service life, technical services and relevant responsibilities

− If the tender document is deviated from the technical document of the tender, a deviation list shall be given in the tender documents

− Data sheets of materials and structures of components

− Others

6.6.2 Documents to be Submitted after Ordering

The Vendor shall provide the CONTRACTOR with the following drawings and documents (6 paper copies and 2 electronic copies) within two weeks after signing the Contract:

− Structural drawings, installation outline drawings, and manufacturing drawings of wearing parts

− Installation outline drawings of valves and actuators

− Structures of valve disks, seats, and seals

6.6.3 Documents to be Submitted during Delivery When a valve is delivered, the Vendor shall provide the CONTRACTOR with the following drawings and documents (6 paper copies and 2 electronic copies):

− Operation manual

− Installation and Maintenance Manual

− Drawings and documents of actuators

− The test report of the chemical composition and mechanical property of the materials for the valve

− Hydraulic and pneumatic testing reports with records of time and pressure changes

− Corresponding nondestructive flaw detection report

− Valve operation test report

− Other test reports and certificates as required by API 6D

− Others

6.7 Packing and Shipping

Preparation for packing and shipping shall be in accordance with CONTRACTOR’s requirements for protection during transit and storage. All openings on the valves must be positively sealed by 1/8" spool blanking plates or other methods to ensure against ingress of dirt and transportation hazards. The use of adhesive tape closure alone is prohibited.




Easily damaged parts such as machined faces, hand wheels, etc., shall be fitted with caps, plates, etc., for protection. Machined or threaded surfaces exposed to the atmosphere in shipment or storage shall be coated with rust preventative. Wherever possible (e.g., in crates, etc.) the valve is to be transported in an upright position to minimise galling of valve seat due to vibration. Valves and components made of austenitic stainless steel must be stored under cover and out of contact with the ground and shall not be exposed to salt water or spray. Following testing, all components, especially valve body cavities, are to be thoroughly dried prior to preparation for packing and shipping. All gasket surfaces are to be thoroughly cleaned prior to preparation for packing and shipping.

6.8 Technical Services

6.8.1 Technical Support − The Vendor shall provide the valve installation procedure.

− The Vendor shall provide the special tools for field installation.

− The Vendor shall assign experienced engineers to provide guidance to field installation. When the CONTRACTOR informs the Vendor of putting into operation, the Vendor shall cooperate in trial operation and debugging.

− When equipment is out of order or cannot meet operation requirements, the Vendor shall eliminate the fault.

− When equipment needs to be repaired or its components need to replaced, the Vendor shall assign experienced engineers to provide field technical support as required by the CONTRACTOR.

− The fee for technical services shall be borne by the Vendor.

6.8.2 Training − The Vendor shall train operating personnel in installation and maintenance.

6.9 Acceptance

6.9.1 Factory Acceptance

A notice shall be given to the CONTRACTOR two months ahead of delivery, and the CONTRACTOR determines whether to assign personnel to perform preliminary factory acceptance and to check the quality record during product processing, production performance inspection report and combined debugging etc. The CONTRACTOR shall sign and approve delivery.

6.9.2 Acceptance after AOG

After goods arrive the storehouse (or site) designated by the CONTRACTOR, the Vendor assign personnel to unpack and accept the goods. The representative




designated by the COMPANY, the CONTRACTOR and the Vendor shall sign and confirm the goods. 6.9.3 Intermediate Acceptance

The Vendor shall assign site service engineers to perform final inspection and commissioning and supervise installation of the product on site. The site supervisor, the construction unit and the site service engineers shall sign and confirm. 6.9.4 Final Acceptance

The whole pressure shall be kept for over 72 hours during test run of the whole line of the project. The COMPANY, the CONTRACTOR and the CONTRACTOR shall sign and confirm.

6.10 After-sale Services

When equipment is out of order or cannot meet the CONTRACTOR/COMPANY’s operation requirements, the Vendor shall eliminate the fault as required by the CONTRACTOR/COMPANY till reaching the CONTRACTOR/COMPANY’s requirements. When equipment needs to be repaired or its components need to replace within the maintenance period, the Vendor shall assign experienced engineers to provide field technical support as required by the CONTRACTOR/COMPANY. When the CONTRACTOR/COMPANY requires the Vendor to provide services, the Vendor shall give a reply within 24 hours, and if necessary, shall assign a service engineer to reach the site within 48 hours. If there is a must for assigning personnel abroad, the allotment time shall not exceed 20 days. Within the warranty period, the Vendor shall be responsible for giving a definite written reply to the quality questions posed by the CONTRACTOR. In case of any quality problem, the Vendor has to adopt protective measures in a timely manner, replace free of charge and lengthen the warranty period. Within the life period of the product, the Vendor shall ensure supply of all spare parts. When the Vendor supplies spare parts, the allotment time shall not exceed 48 hours at home and 20 days abroad.

6.11 Guarantee and Warranty

The Vendor shall ensure that all valves will not be of material, design and manufacturing technology defects etc. during use. If the above defects occur during use, the Vendor shall carry out necessary replacement and maintenance free of charge. If any defect or fault occurs within the guarantee period, the Vendor shall provide replacement, maintenance, shipping and site labor services free of charge. The guarantee period shall be 18 months as of cargo departure date or 12 months as of cargo arrival destination port date, whichever is sooner.