Contract File Reference Page

Number:P1007 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 Fawzi A Hamdan RWE

A Khamisy

0 31.10.11 Issued for Client comment A Saleh / A Fawzi A Hamdan RWE

A Khamisy

Rev Date Description Issued By Checked Approved Client

By By Approval
 Onspec Engineering Solutions
Disouq Field Development Project
Shutdown Valve Specification

Changes List
Date
Rev. prepared Prepared by Description
(dd.MMM.yyyy)
A Saleh / Modified the document to comply with RWE
01 11.11.2011 A Khamisy comments.

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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 Pneumatic Valve Operator Data Sheet

2 Electric Valve Operator Data Sheet
3 Hydraulic Valve Operator Data Sheet

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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 1007-DISQ-0-J-SS-33010
Testing Requirements

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

Vendor Supplier is the party, which manufactures or supplies equipment

1.3 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

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SSSV Subsurface Safety Valve

RMS Root Mean Square

SPDT Single Poles Double Throw

NAMUR Normen Ausschuss fr Mess- und Regeltechnik

OCMA Oil Companies Materials Association

1.4 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 C
Pressure (gauge) Psig
Pressure (absolute) Psia
LEVEL % of range; or mm for tanks
Mass Kg
Area m
Length M
Liquid absolute density kg/m (@ 15 C)
Vapour flowing density kg/m
Flow rate (gas) MMscfd
Flow rate (liquid) bbl/d
Time S
Velocity m/s
Enthalpy J/kg
Viscosity cP
Electrical Power kW, MW
Voltage V, mV
Current A, mA
Electric resistance Ohm
Frequency Hz
Speed RPM

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Shutdown Valve Specification

1.5 Climate Condition

The shutdown valves shall be suitable to operate in the north delta climate conditions:

Ambient Temperatures 0 C to 35 C normal, up to 50 C maximum

Metal Surface C 85 C

Humidity range (Min. & Max) 60 to 75%

Average Rainfall app. 200 mm/year with possible showers during Nov-
March

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

Wind Speed & Direction Predominant NW direction, max. 39-44 m/s

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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

Pipe Threads (Except Dryseal) Specifications, Dimensions, and Gauging for

B2.1
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

Liquid Transportation Systems for Hydrocarbons, Liquid Petroleum Gas,
B 31.4
Anhydrous Ammonia, and Alcohols
B 31.8 Gas Transmission and Distribution Piping Systems

Valves - Flanged and Buttwelding End Steel, Nickel Alloy and Other Special
B16.34 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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Shutdown Valve Specification

2B Specification for Fabricated Structural Steel Pipes

Recommended practice for classification of locations for electrical installations

500
at petroleum facilities classified as Class 1, Division 1 and Division 2.

5L Specification for Line Pipe

Specifications for Pipeline Valves, End Closures, Connectors and Swivels
SPEC 6D
Fire Test for Soft Seated Ball Valves
STD 607

Manual on Installation of Refinery Instruments and Control Systems, Part 1 -

RP 550 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 / Specification for Alloy Steel and Stainless Steel Bolting Materials for
A193M High Temperature Service
Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High-
A194 Pressure
/ High-Temperature Service
Standard Specification for Piping fittings of Wrought Carbon Steel and Alloy
A234
Steel for Moderate and Elevated Temperatures
Standard Specification for Seamless and Welded Austenitic
A269
Stainless Steel Tubing for General Service
Specification for Seamless and Welded Austenitic Stainless Steel Tubing
A269
for General Service
Specification for Alloy Steel Bolting Materials for Low
A320
Temperature Service
High Strength Bolts for Structural Joints, including Suitable
A325
Nuts and Plain Hardened Washers
Methods and Definitions for Mechanical Testing of Steel
A370
Products.
Standard Specification for Wrought Austenitic Stainless Steel
A403
Piping Fittings
Standard Specification for General Requirements for Carbon
A450/450M
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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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

Standard for the Installation of Air Conditioning and
90A
Ventilation Systems
493 Intrinsically Safe Apparatus
Standard for Purged and Pressurized Enclosures for
496
Electrical Equipment in Hazardous (Classified) Locations
International Electro-technical Commission (IEC)
Insulation co-ordination within low-voltage systems including
664
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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Shutdown Valve Specification

3 SHUTDOWN VALVE

3.1 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.

3.2 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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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 -20F (-34C) to 750F (400C).
o 316 stainless steel for corrosive service application or noncorrosive service
applications with operating temperatures below -20F (-34C) and greater than
750F (400C).
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 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.

4.1.1 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.

4.1.2 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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Shutdown Valve Specification

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.

4.2 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.

4.3 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 fail-
closed 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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Shutdown Valve Specification

Valve actuator assemblies shall be sized according to the manufacturers

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.

4.3.1 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.

4.3.2 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.

4.4 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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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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Shutdown Valve Specification

Shutdown valve shall be equipped with a manufacturers 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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