1007 DISQ 0 J SS 33033 Shutdown Valve Specification

Contract Number:P1007

File Reference

Page

1007-DISQ-0-J-SS-33033-Rev.1

1 of 15

RWE Dea

Disouq Field Development FEED

Shutdown Valve Specification

Document number 1007-DISQ-0-J-SS-33033

1

15.11.11 Issued for Client Approval

A Saleh / A Khamisy

A Fawzi

A Hamdan

RWE

0

31.10.11 Issued for Client comment

A Saleh / A Khamisy

A Fawzi

A Hamdan

RWE

Issued By

Checked By

Approved By

Client Approval

Rev

Date

Description

Onspec Engineering Solutions Disouq Field Development Project Shutdown Valve Specification

Changes List Rev.

Date prepared (dd.MMM.yyyy)

01

11.11.2011

Prepared by A Saleh / A Khamisy

Description Modified the document to comply with RWE comments.

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Onspec Engineering Solutions Disouq Field Development Project Shutdown Valve Specification

Table of Contents 1

Introduction .................................................................................................................. 4

1.1

Scope ........................................................................................................................... 4

1.2

Definitions .................................................................................................................... 4

1.3

Abbreviations ............................................................................................................... 4

1.4

Units of Measurements ................................................................................................ 5

1.5

Climate Condition ......................................................................................................... 6

2

APPLICABLE CODES AND STANDARDS .................................................................. 7

3

SHUTDOWN VALVE.................................................................................................. 10

3.1

Application ................................................................................................................. 10

3.2

Valve Rating and Valve Class .................................................................................... 10

3.3

Valve Maintainability................................................................................................... 10

3.4

Basis of selection ....................................................................................................... 10

3.5

Valve Sizing ............................................................................................................... 10

3.6

Body ........................................................................................................................... 11

3.7

Connections ............................................................................................................... 11

4

VALVE TYPES & ACCESSORIES ............................................................................. 11

4.1

Process Service Valves .............................................................................................. 11

4.1.1 Ball Valves ................................................................................................................. 11 4.1.2 Butterfly Valves .......................................................................................................... 11 4.2

Wellhead Service Valves ............................................................................................ 12

4.3

Valve Actuator ............................................................................................................ 12

4.3.1 Air Actuators .............................................................................................................. 13 4.3.2 Hydraulic Actuators .................................................................................................... 13 4.4

Valve Accessories ...................................................................................................... 13

5

TAGGING AND NAMEPLATES ................................................................................. 14

6

DOCUMENTATION.................................................................................................... 15

7

REVIEW & APPROVAL ............................................................................................. 15

8

QUALITY ASSURANCE PROVISIONS ...................................................................... 15

ATTACHMENTS 1 2 3

Pneumatic Valve Operator Data Sheet Electric Valve Operator Data Sheet Hydraulic Valve Operator Data Sheet

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Onspec Engineering Solutions Disouq Field Development Project Shutdown Valve Specification

1 Introduction 1.1 Scope This specification covers the minimum technical requirements for the design, manufacture and testing of shut down and Blow down (On/Off) valves assemblies and accessories suitable for installation on RWE Disouq Field Development Project. The following documentations shall be considered necessary for shut down and Blow down valves Selection such as: Document

Reference no.

P&ID

1007-DISQ-0-P-DW-48031 to 480xx (HOLD)

Process Flow Diagrams

1007-DISQ-0-P-DW-48031 to 48017

Shut Down Valve Data Sheets

(HOLD)

Instrumentations General Specifications and Testing Requirements

1007-DISQ-0-J-SS-33010

Shutdown and blowdown valves shall include, but not limited to, the shutdown valve, actuator, regulator, solenoid, pilot valve, lubricator, limit switches, hydraulic hand pump. For a specific and blowdown valve, this specification shall be used in conjunction with the Technical Requirements. 1.2

Definitions

Company

Supplier is the party, which manufactures or supplies equipment

Vendor

1.3

RWE Dea Egypt, in a later project state a JV formed between the RWE Dea Egypt and EGAS

Abbreviations

ANSI

American National Standards Institute

API

American Petroleum Institute

MSS

Manufacturers Standardization Society of the Valve and Fittings Industry

NACE

National Association of Corrosion Engineers

NEMA

National Electrical Manufacturers Association

NFPA

National Fire Protection Association

CENELEC

European Committee for Electrotechnical Standardization

IEC

International Electro-technical Commission

CTP

Central Treatment Plant

RF

Raised Face

SC

Surface Controlled Page: 4 of 15

Onspec Engineering Solutions Disouq Field Development Project Shutdown Valve Specification

SSSV

Subsurface Safety Valve

RMS

Root Mean Square

SPDT

Single Poles Double Throw

NAMUR OCMA

1.4

Normen Ausschuss für Mess- und Regeltechnik Oil Companies Materials Association

Units of Measurements

Units of Measurements shall be in accordance to the International System of Units (SI System), the following units shall be used in all documents, including drawings, and for all purpose under the scope of work. Units of measurement to be applied: Temperature Pressure (gauge) Pressure (absolute) LEVEL Mass Area Length Liquid absolute density Vapour flowing density Flow rate (gas) Flow rate (liquid) Time Velocity Enthalpy Viscosity Electrical Power Voltage Current Electric resistance Frequency Speed

ºC Psig Psia % of range; or mm for tanks Kg m² M kg/m³ (@ 15 °C) kg/m³ MMscfd bbl/d S m/s J/kg cP kW, MW V, mV A, mA Ohm Hz RPM

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Onspec Engineering Solutions Disouq Field Development Project Shutdown Valve Specification

1.5 Climate Condition The shutdown valves shall be suitable to operate in the north delta climate conditions: Ambient Temperatures

0 ºC to 35 ºC normal, up to 50 ºC maximum

Metal Surface °C

85 ºC

Humidity range (Min. & Max)

60 to 75%

Average Rainfall

app. 200 mm/year with possible showers during NovMarch

Seismic Zone

Moderate risk, 10% probability to exceed 0.8 m/s² Ground acceleration in 50 years

Wind Speed & Direction

Predominant NW direction, max. 39-44 m/s

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Onspec Engineering Solutions Disouq Field Development Project Shutdown Valve Specification

2 APPLICABLE CODES AND STANDARDS The design, construction, testing and general requirements shall comply with the latest edition of applicable codes and standards. The Vendor shall consider the most recent codes and standards issued by the following associations and approved bodies as part of this specification.

Reference

Title

American National Standards Institute (ANSI) B 1.20.1

Standard for Pipe Threads, General Purpose

B2.1

Pipe Threads (Except Dryseal) Specifications, Dimensions, and Gauging for Taper and Straight Pipe Threads Including Certain Special Applications

B16.20

Ring-Joint Gaskets and Grooves for Steel Pipe Flanges

B 16.47

Large Diameter Steel Flanges NPS 26 Thru NPS 60

B16.5

Pipe Flanges and Flanged Fittings

B 16.9

Factory Made Wrought Steel Buttwelding Fittings

B 16.11

Forged Steel Fittings, Socket Welding and Threaded

B 31.1

Power Piping Code

B 31.3

Chemical Plant and Petroleum Refinery Piping

B 31.4

Liquid Transportation Systems for Hydrocarbons, Liquid Petroleum Gas, Anhydrous Ammonia, and Alcohols

B 31.8

Gas Transmission and Distribution Piping Systems

B16.34

Valves - Flanged and Buttwelding End Steel, Nickel Alloy and Other Special Alloys

B16.104

Valve Leakage Classifications

B 36.10M

Welded and Seamless Wrought Steel Pipe

C 37.96

IEEE Guide for AC Motor Protection

American Petroleum Institute (API) 1104

Standard for Welding of Pipelines and Related Facilities

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Onspec Engineering Solutions Disouq Field Development Project Shutdown Valve Specification

2B

Specification for Fabricated Structural Steel Pipes

500

Recommended practice for classification of locations for electrical installations at petroleum facilities classified as Class 1, Division 1 and Division 2.

5L

Specification for Line Pipe

SPEC 6D STD 607

Specifications for Pipeline Valves, End Closures, Connectors and Swivels Fire Test for Soft Seated Ball Valves

RP 550

Manual on Installation of Refinery Instruments and Control Systems, Part 1 Process Instrumentation and Control, Section 6 - Control Valves and Accessories

554

Process Control and Instrumentation

SPEC 6D

Specifications for Pipeline Valves, End Closures, Connectors and Swivels

American Society for Testing and Materials (ASTM) A193 / A193M A194 A234 A269 A269 A320 A325 A370 A403 A450/450M

Specification for Alloy Steel and Stainless Steel Bolting Materials for High Temperature Service Standard Specification for Carbon and Alloy Steel Nuts for Bolts for HighPressure / High-Temperature Service Standard Specification for Piping fittings of Wrought Carbon Steel and Alloy Steel for Moderate and Elevated Temperatures Standard Specification for Seamless and Welded Austenitic Stainless Steel Tubing for General Service Specification for Seamless and Welded Austenitic Stainless Steel Tubing for General Service Specification for Alloy Steel Bolting Materials for Low Temperature Service High Strength Bolts for Structural Joints, including Suitable Nuts and Plain Hardened Washers Methods and Definitions for Mechanical Testing of Steel Products. Standard Specification for Wrought Austenitic Stainless Steel Piping Fittings Standard Specification for General Requirements for Carbon Steel, Ferritic Alloy, and Austenitic Alloy Steel Tubes.

American Society of Mechanical Engineers (ASME) Section II

Material Specifications

Section VIII

Pressure Vessels

Section IX

Welding and Brazing Qualifications

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Onspec Engineering Solutions Disouq Field Development Project Shutdown Valve Specification

National Electrical Manufacturers Association (NEMA) ICS-2

Industrial Control Devices, Controllers and Assemblies

MG-1

Motors and Generators

250

Enclosures for Electrical Equipment

National Fire Protection Association (NFPA) 70

National Electrical Code

90A

Standard for the Installation of Air Conditioning and Ventilation Systems

493

Intrinsically Safe Apparatus

496

Standard for Purged and Pressurized Enclosures for Electrical Equipment in Hazardous (Classified) Locations

International Electro-technical Commission (IEC) 664

Insulation co-ordination within low-voltage systems including clearances and creep age distances for equipment

60059

IEC Standards Current Ratings

60085

Thermal Evaluation and Classification of Electrical Insulation

60228

Specification for conductors in insulated cables.

60331

Test for electric cables under fire conditions – Circuit integrity

60529

Degrees of protection provided by enclosures (IP Code)

60534

Industrial Process Control Valves Inspection & Routine Testing

Instrument Society of America (ISA) S75.01

Control Valve Sizing Equations

S75.02

Control Valve Capacity Test Procedures

S75.03

Uniform Face-to-face Dimensions for Flanged Globe Style Control Valve Bodies

S75.04

Face-to-face Dimensions of Flangeless Control Valves

Manufacturers Standardization Society of the Valve and Fittings Industry (MSS) SP 61

Pressures Testing of Steel Valves

National Association of Corrosion Engineers (NACE) MR-01-75

Sulfide Stress Cracking Resistant Metallic Material for Oil Field Equipment

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Onspec Engineering Solutions Disouq Field Development Project Shutdown Valve Specification

3 SHUTDOWN VALVE 3.1 





3.2  



Application The shutdown valve assembly stops the flow in a piping system / well head during an emergency situation. The shutdown valve and accessories are installed on wellhead flow lines to shuts down the well head. Shutdown valves are also installed in the central treatment plant (CTP) process piping systems to shutdown plant areas and segregate the plant into sections. Specific shutdown and Blowdown valves performance requirements shall be as described on the specific shutdown and Blowdown valves assembly data sheets. Shutdown valve shall be classified for either wellhead shutdown service or process shutdown service. Wellhead service shutdown valves shall conform to the requirements listed in API Specification 14D, “Specification for Wellhead Surface Safety Valves”. Valve Rating and Valve Class The pressure rating for a specific shutdown valve shall be the same as the piping application. The minimum shutdown valve rating shall be 150 PSIG. Shutdown valves intended for no wellhead application shall have a minimum leakage class rating under the non fire conditions of Class V as defined by ANSI B16.104, “Valve Leakage Classifications”. Process service shutdown valves in piping containing combustible materials or in piping subject to fire conditions shall be rated fire safe. The minimum temperature rating for fire safe valves shall be 2000 °F (1095 °C). Valves meeting API standard 607, Fire Test for Soft Seated Ball Valves, are acceptable if approved by the Company.

3.3 

Valve Maintainability The emergency shutdown valve assembly shall not require any maintenance other than routine cleaning of the exterior surfaces and periodic lubrication.

3.4 

Basis of selection The vendor shall be responsible for the selection of Shut down and Blow down Valves suitable for its intended application as specified in the Technical Requirements All shutdown and blowdown valves shall be in according to applicable piping class. All wetted and mounting parts are to be as per applicable piping material. The shutdown valves are to be flanged mounted only. Construction material, shall be as specified in the Technical Requirements Any proposed deviation from the approved material list shall be approved in writing by the Company.



 

3.5    

Valve Sizing Shutdown valves shall be sized to pass a minimum of 120 percent of the maximum design flow rate. The minimum valve body size shall be 1 inch. Odd valve body sizes such as 1 1/4 inches, 2 1/2 inches or 5 inches shall not be acceptable. Reduced port valves shall be acceptable when in accordance with the piping specification.

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Onspec Engineering Solutions Disouq Field Development Project Shutdown Valve Specification

3.6 

Body The valve body shall be constructed from materials as specified in the Technical Requirements, including the shutdown valve engineering data sheets and piping classification and as defined by ASTM A182/A182M. The minimum valve body requirements are: o Cast or forged carbon steel for noncorrosive application with an operating temperature of -20°F (-34°C) to 750°F (400°C). o 316 stainless steel for corrosive service application or noncorrosive service applications with operating temperatures below -20°F (-34°C) and greater than 750°F (400°C). o Bronze, cast iron and plastic are not acceptable for valve bodies.

3.7  

Connections Valve body connection shall be flanged in accordance with the piping specifications. Flanged connections shall conform to the requirement of ANSI B16.5, Pipe Flanges and Flanged Fittings.

4 VALVE TYPES & ACCESSORIES 4.1       

4.1.1   

4.1.2 

Process Service Valves Ball, butterfly type valves shall be provided in process shutdown applications. Ball valves shall be provided for all Process Service Valves from 2 inches or greater and a flange rating of 900 pounds or less. Butterfly type valves shall be provided only for backup or low risk application requiring valves 12 inches and larger and a low differential pressure. Globe type valves are not acceptable for process service applications. Process service valves (excluding gate valves) shall have a valve actuation travel of 90 degrees (90-degree turn type). Valve operation shall minimize valve seat and seal wear. Flangeless valves (ball or butterfly valves which must be installed between process piping flanges with exposed bolts) are not acceptable for emergency shutdown application, even when metal shields are installed around the exposed bolts. Ball Valves All trunnion mounted valves greater than or equal to 2” NPS shall be designed to API 6D / ISO 14313. Valves shall also incorporate the requirements of ASME B16.34 for the wall thickness design and the pressure / temperature rating of the valve. Ball valves shall be utilised for actuated on-off valves and shall be designed in accordance with the latest editions of the specified standards and the additional requirements of this specification, with any deviations to these requirements highlighted by the valve Supplier during the RFQ stage. Butterfly Valves Butterfly valves shall be of the eccentric disc, lug type with a carbon steel body and stainless steel trim.

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Onspec Engineering Solutions Disouq Field Development Project Shutdown Valve Specification

   



4.2      

4.3   

   

Butterfly valves shall be designed in accordance with API Specification 6D or ANSI B16.34, Valves - Flanged Butt welding End Steel, Nickel Alloy, and Other Special Alloys. The valves shall be capable of mating with raised faced (RF) flanges with ANSI ratings according to the data sheets. Low-pressure butterfly valves with a 150 pound per square inch (PSI) rating are not acceptable. The valves shall be fire safe and shall meet one or more accepted industry valve fire testing standards. The vendor shall state the standard under which the valve has been tested. Valve seats have primary resilient seal and secondary metal to metal seals. The seals shall provide dead tight service. Wellhead Service Valves Wellhead service shutdown valves shall be gate type valves and shall conform to the requirements of API Specification 14D. Globe type valves are not acceptable for wellhead service applications. Gate valves shall be of the full-bore, reverse acting slab type with a carbon steel body and raised faced (RF) flanges. Gate valves shall be designed in accordance with API Specification 6D, Specification for Pipeline Valves. Valves shall be provided with two floating seats. Each seat shall have a primary resilient seal and a secondary metal to metal seal. The seals shall provide dead tight service. Valves shall be provided with a means to relieve pressure from the body cavity when the valve is closed. Valve Actuator Valve control shall be from either pneumatically operated actuators or hydraulic actuators. Valve actuators shall be either spring return piston or double action piston. Pneumatically-operated, spring-return, piston actuators are preferred for fail-open or failclosed valve applications. Hydraulically-operated, piston actuators shall be limited to applications where: o Pneumatically-operated piston actuators cannot produce the required torques with the given air supply pressures. o The physical size of a pneumatically-operated actuator presents major installation problems or is otherwise not cost-effective. o Surface-Controlled, Subsurface Safety Valves (SC, SSV) and Surface Safety Valves for wellheads. Spring and diaphragm or motor driven actuators for emergency shutdown service are not acceptable. All actuators shall be failsafe and shall fail closed or fail open as required by Technical Requirements. The maximum valve rotation from a fully closed to a fully open position shall be limited to 90 degrees. The control air pressure available will be 100 pounds per square inch gauge (PSIG) nominal, 150 PSIG maximum, and 80 PSIG minimum. Actuators shall be capable of withstanding a maximum pressure of 150 PSIG.

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Onspec Engineering Solutions Disouq Field Development Project Shutdown Valve Specification



        



4.3.1 



4.3.2    4.4 



Valve actuator assemblies shall be sized according to the manufacturer’s recommendations. Starting and ending torques shall be 1.5 times greater than the breakaway torque of the valve. Actuator sizing shall be based on opening the valve with a differential pressure in the valve body equal to the ANSI maximum cold working pressure of the valve flanges. Actuators shall have single shafts constructed of 316 stainless steel or K-Monel. Split shafts are not acceptable. The shaft shall be extended through the cylinder head and designed for operation with a detachable manual operator. The shaft shall be protected with a clear plexi glass cover. Actuator shall be capable of performing satisfactorily for at least 4 hours at an ambient temperature of 400 °F (205 °C). If the working pressure of the cylinder is exceeded, actuator shall be designed to relieve pressure from both sides of the piston. The cylinder wall shall be of carbon steel or stainless steel. The inside cylinder wall shall have a corrosion resistant, smooth finish. The inside wall shall be machined finish to less than 32 micro inches, root mean square (RMS). The following methods of corrosion protection are acceptable: o After machining, the inside wall shall be coated with a thermosetting multipolymer epoxy, such as Marchem PT-201, followed by a lubricant film of molybdenum disulfide, such as Teclube PT-201. o After machining, the inside wall shall be nickel electrolysis plated, 1 to 2 mils thick. Any grease fitting for lubrication of stem packing shall have an internal check valve to prevent backflow. Air Actuators Pneumatically operated, spring return actuators shall be capable of producing one complete valve actuation (fully closed to fully open to fully closed) with a pressure of 80 PSIG. Double action actuators shall be capable of producing one complete valve actuation (fully closed to fully open to fully closed) with a pressure of 60 PSIG. Hydraulic Actuators Hydraulically operated actuators shall have a spring return. Actuators shall be supplied from a reservoir hydraulic supply. Only one actuator shall be connected per reservoir supply. The hydraulic fluid shall be fully biodegradable oil e.g. castrol transaqua or equal. Valve Accessories The available control air pressure shall be 100 PSIG nominal, 150 PSIG maximum, and 80 PSIG minimum. Accessories shall be capable of withstanding a maximum pressure of 150 PSIG. Valves shall have an integral valve position indicator, linked to the shaft.

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Onspec Engineering Solutions Disouq Field Development Project Shutdown Valve Specification



 





  

  



Proximity limit switches shall contain two single poles double throw (SPDT) switches and shall be intrinsically safe contacts. The switches shall be hermetically sealed and attached to the moving member of the valves (not to the actuator). Switches shall be housed in an explosion proof enclosure. The minimum contact rating shall be 3 amps. Switches shall close on proximity (i.e., open during valve travel). Pneumatically-operated actuators on process service shutdown valves shall not have a hand wheel to position the valve manually. If the control system is electric, shutdown valves shall be operated by solenoid valves. It shall be intrinsically safe type and it shall be installed on the actuated valve actuator in accordance to NAMUR Worksheet NA19. The enclosure shall at least IP65. The air passages in the solenoid valves shall be large enough to achieve the opening or closing time of the valve as stated in the instrument data sheet where this would lead to unrealistically large passages and consequently high power consumption of the solenoid valve, consideration should be given to the use of quick-exhaust valves. The solenoid coil shall be of the epoxy-encapsulated type. The solenoid shall be of the three-way type with a 316 stainless steel body. Port size and coil voltage shall be as stated in the Technical Requirements. Solenoid valves shall be provided with a integral termination box for connection of the leads All solenoid valves for the emergency shutdown system located in hazardous areas in zone 1/ zone 2 shall be Ex (i) classified and shall be according to IEC Standard. None intrinsically safe solenoid valves are not allowed. All solenoid valves are to be SIL2 rated as minimum. If the control system is pneumatic, shutdown valves shall be operated by pilot valves. The pilot valves shall be mounted on the shutdown valves and shall be three-way, 316 stainless steel valves. Port size and pressure rating shall be as stated in the Technical Requirements. Instrument air pressure available to the sensing port of pilot valves shall be 30 to 60 PSIG. The three-way pilot relay valves supplied with each actuator shall be in accordance with the Instrument Hook-Up Drawings (1007-DISQ-0-J-SS-22012). If manual reset is specified, the pilot relay valve shall be supplied with a manual override handle that will close the shutdown valve when the handle is pulled out. The manual handle shall latch when closing the shutdown valve. No lock open device shall be allowed to latch the pilot valve in the open position manually. Manual reset pilots shall be remotely mounted when the valve accessory mounting plate is not easily accessible due to valve mounting position or location. Solenoid valves and pneumatic pilot relay valves shall be provided with failsafe action to close the shutdown valve if the electric signal or instrument air signal is lost. All tubing and fittings shall be 316stainless steel. Accessories not mounted directly on the valve shall be mounted on a 316 stainless steel mounting plate. The mounting plate shall be bolted to the actuator/valve assembly with 316 stainless steel bolts. Valves in liquid or two-phase flow service shall be equipped with adjustable controls to vary the valve closing speed.

5 TAGGING AND NAMEPLATES

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Onspec Engineering Solutions Disouq Field Development Project Shutdown Valve Specification

Shutdown valve shall be equipped with a manufacturer’s nameplate of 316 stainless steel permanently attached with stainless steel screws or rivets indicating the specified data. In addition to specified data the following data shall be provided which is a minimum:  Valve serial number  Tag number  Valve model number or catalogue number  Valve manufacturer  Valve inlet and outlet connection sizes and rating  Pressure and temperature rating of the internal pressure retaining components.  Operating ranges and materials of the parts exposed to the process fluid.

6 DOCUMENTATION Documentation shall be provided in accordance with the Technical Requirements, with the following additional requirements.  The Vendor shall supply the wide open flow coefficient (Cv) for each valve.  The Vendor shall state the pneumatic volume required and the estimated range of closing time (zero pressure to maximum differential pressure in valve body) for each valve. The Vendor shall also submit the basis for actuator sizing (charts/calculations) for each valve.  The Vendor shall state the pneumatic volume required, estimated time for operating, torque requirements for each valve including safety factor and torque output of the associated actuator.

7 REVIEW & APPROVAL Company will respond to vendor documentation approval requests within two weeks of receipt of information. Company approval in no way relieves the vendor of any responsibility for compliance with the Technical Requirements.

8 QUALITY ASSURANCE PROVISIONS Quality assurance provisions shall be in accordance with the Technical Requirements, and as follows: 





The valve/actuator assembly Vendor shall test operation of the valve, actuator and all the accessories that are installed and connected. Tests shall be designed to prove operability of the valve and actuator assembly under simulated operating conditions. The valve, actuator, associated components and pneumatic system shall be tested in the completely assembled state. Inspections and testing of the valves shall be performed by the Vendor in accordance with API Specification 6D and ANSI B16.5. Company reserves the right to inspect the valve/actuator assemblies at any time during fabrication to ensure that the materials and workmanship are in accordance with the Technical Requirements, and the applicable standards and codes. Butterfly valves shall be tested by the valve manufacturer in accordance with ANSI B16.34 and MSS SSP 61. Pressure Testing of Steel Valves, prior to being shipped to the valve/actuator assembly Vendor.

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