Project Specification Control Valve.pdf

OURHOUD-Organisation Ourhoud

PROJECT SPECIFICATION

ORGANISATION OURHOUD REALISATION DES INSTALLATIONS DE PRODUCTION D’HUILE OURHOUD, ALGERIE CT-99-010-040

SPECIFICATION FOR CONTROL VALVES

AS BUILT

CONTENTS 1. Introduction ................................................................................................................................ 4 1.1 General Description of Development ................................................................................. 4 1.2 Objective............................................................................................................................... 4 1.3 Project Schedule .................................................................................................................. 4 1.4 Project Communications ..................................................................................................... 4 1.5 Design Responsibility .......................................................................................................... 5 1.6 Approvals ............................................................................................................................. 5 1.7 Definitions ............................................................................................................................ 5 2. References ................................................................................................................................... 5 2.1 International Codes and Standards ................................................................................... 5 2.2 Project Documents ............................................................................................................... 6 3. Scope of supply ........................................................................................................................... 6 3.1 General ................................................................................................................................. 6 3.2 Spares ................................................................................................................................... 7 4. Design requirements ................................................................................................................... 7 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10

General ................................................................................................................................. 7 Environmental Conditions.................................................................................................. 7 Radio Interference ............................................................................................................... 8 Electromagnetic Compatibility (EMC) ............................................................................. 8 Ingress Protection ................................................................................................................ 9 Utilities .................................................................................................................................. 9 Process Data ......................................................................................................................... 9 Control Valve Sizing and Characteristics ......................................................................... 9 Noise .................................................................................................................................... 10 Stroking Times ................................................................................................................... 10

4.11 Calculations ........................................................................................................................ 10 4.12 Maintainability .................................................................................................................. 10 4.13 Hazardous Area Requirements ........................................................................................ 10 5. Equipment requirements ......................................................................................................... 11 5.1 Valve Construction ............................................................................................................ 11 5.2 Control Valve Actuators ................................................................................................... 11 5.3 Materials ............................................................................................................................. 12 5.4 Flange Ratings ................................................................................................................... 13 5.5 Ancillary Equipment ......................................................................................................... 13 5.6 Labels .................................................................................................................................. 14

5.7 Painting............................................................................................................................... 14 6. Preparation for shipment......................................................................................................... 14 6.1 Cleaning and Preservation................................................................................................ 14 6.2 Packing ............................................................................................................................... 15 6.3 Shipment............................................................................................................................. 15 7. TESTING AND COMMISSIONING ..................................................................................... 15 7.1 General ............................................................................................................................... 15 7.2 Test Procedures ................................................................................................................. 16 7.3 Test Equipment.................................................................................................................. 16 8. Documentation .......................................................................................................................... 16 8.1 General ............................................................................................................................... 16 8.2 Post-Order Documentation ............................................................................................... 16

1. Introduction 1.1 General Description of Development

The Ourhoud field is located in Eastern Central Algeria in the Hassi Berkine basin approximately 320 km South East of Hassi Messaoud and 1200 km South East of Algiers. The reservoir area is approximately 20 km long by 4 km wide and extends across three blocks, namely 404, 405 and 406a. The anticipated maximum nominal oil production is 230,000 barrels of oil per day (BOPD) for approximately 8 years and then declines progressively to 19,000 BOPD at year 25 (field design life). Gas produced will be used as fuel gas or for gas lift and any surplus re-injected. The Development comprises a Central Processing Facility (CPF), seven satellite stations and approximately seventy wellheads (oil production, gas injection, water injection, source water and utility water). The Client is Organisation Ourhoud. 1.2

Objective This Specification defines the minimum requirements for modulating control valves for the CPF, satellite stations and oil production wellheads. The Specification is written to outline general requirements for the control valves but it must be read in conjunction with the other Codes, Standards and Specifications referenced in Section 2. The majority of the control valves at the CPF will be of the conventional, single seated, globe type, with pneumatic actuators. However, control valves at the satellite stations will have integral electro-hydraulic actuators. Certain valves will be defined for arduous duty or noise suppression applications. The objective of this document is to identify general requirements. Data sheet for Control Valves, which provide a schedule of the control valves currently identified, is issued separately from this specification.

1.3

Project Schedule The Supplier shall include, with his Proposal, a planning chart with milestones and completion dates. The chart shall be updated with actual progress during the design and construction periods.

1.4

Project Communications Verbal agreements between Supplier and Purchaser shall not be official until confirmed in writing by the Purchaser. All post-Order Project communications shall be in English and French.

1.5

Design Responsibility The Supplier shall be responsible for the design, manufacture, certification, testing and performance of the control valves. This shall include, if appropriate, components and equipment provided by sub-contractors and not manufactured by the Supplier himself.

1.6

Approvals The Purchaser shall approve, prior to manufacture, the following : • Supplier’s documentation, e.g. drawings and design specifications. • Materials of construction. • Manufacturers and Model numbers of sub-contracted equipment. • Test procedures. Any approvals given by the Purchaser shall not release the Supplier from his contractual responsibilities.

1.7

Definitions The following definitions apply throughout this Specification : • Purchaser : JGC/INITEC • Supplier

: Supplier of the goods covered by this Specification.

2. References The design and manufacture of the control valves shall, as a minimum, comply with the following codes and standards as applicable : 2.1

International Codes and Standards

Document Number

Document Title

ASME B16.5 (1996)

Pipe Flanges and Flanged Fittings

ANSI/FCI 70.2 (1998)

Control Valve Seat Leakage

ANSI/ISA S5.1 (1971)

Instrumentation Symbols and Identification

ANSI/ISA S75.01 (1985)

Control Valve Sizing Equations

API 6A (1999)

Specification for Wellhead and Christmas Tree Equipment

API RP 551

Process Measurement Instrumentation

API RP 552

Transmission Systems

API RP 554

Process Instrumentation and Control

IEC 60079-0 (2000)

Electrical Apparatus for Explosive Gas Atmospheres, Part 0:General Requirements

IEC 60079-1 (1998)

Electrical Apparatus for Explosive Gas Atmospheres, Part 1:Construction and Verification Test of Flameproof Enclosures for Electrical Apparatus

IEC 60529 (1989)

Degrees of Protection Provided by Enclosures (IP Code)

IEC 61000

Electromagnetic Compatibility (EMC)

ISO 9000

Quality Systems – Principal Concepts and Applications

ISO 9003 (1994)

Specification for Final Inspection and Test

Note 1. In the case of conflict between the above Codes and Standards, the most stringent shall apply.

2.2

Project Documents Document Number

Document Title

7461-ORH-SP-M-00011 (S-000-13A0-001)

Standard Specification for Coating, Painting and Galvanising

3. Scope of supply 3.1

General The Supplier shall design and supply modulating control valves and ancillaries in accordance with this Specification and Data Sheets for Control Valves. The scope of supply for the control valves shall include, but not be limited to, the design, supply, fabrication, certification, testing and delivery of the complete valve assemblies and provision of required documentation and manuals. Each of the above assemblies shall be fully assembled, piped and tested prior to shipment to ensure functionality and reliability.

The Supplier shall be responsible for the supply, factory assembly and testing of the control valves as detailed in this Specification and as required by the relevant design codes for safe and reliable operation of the valves. The Supplier shall be responsible for the selection of the equipment and materials of construction based on the information supplied in this Specification and referenced documentation. The Supplier shall advise costs for the possible requirement of a specialist site engineer to supervise final installation and commissioning of the control valves. The Supplier’s site engineering services shall include : • Supervision of site testing and any necessary adjustments required. • Confirmation that all control valves are installed in accordance with the Manufacturer’s documentation and recommendations. • Commissioning of the control valves, including demonstration of their correct operation to the satisfaction of the Purchaser and the Algerian authorities. 3.2

Spares The Supplier shall include a priced spares list in his Proposal identifying his recommended spares for pre-commissioning, commissioning and start-up. In addition, the Supplier shall provide a list of recommended 2 years’ operation and insurance spares bearing in mind the remote location of the installation and the associated delays in shipping equipment to site.

4. Design requirements 4.1

General This Specification requires that the design, construction and testing of the control valves shall meet all requirements of the Codes, Standards and other documents listed in Section 2. The Supplier shall also confirm that the control valves offered are suitable for all process conditions specified in the Data Sheets, including conditions expected towards the required design life of 25 years.

4.2

Environmental Conditions The control valves will be mounted in freely ventilated areas throughout the Ourhoud Development. The environmental conditions for these areas are as defined in the

Standard Specification for Environmental Conditions, Utilities, and Transportation, and are summarised in Table 4.1 below : Table 4.1 Environmental Conditions

4.3

Location

Sahara Desert

Elevation

200 m

Latitude

31 ºN

Absolute maximum ambient temperature

60 ºC

Absolute minimum ambient temperature

-2 ºC

Maximum outside design temperature

55 ºC

Minimum outside design temperature

0 ºC

Maximum outside design relative humidity

49 %

Minimum outside design relative humidity

15 %

Mean Rainfall

20 mm/hr

Radio Interference Any electrical equipment shall be immune to interference from hand-held radio transceivers in the immediate vicinity with signal strength of 10 V/m over the range 27 to 500 MHz and shall not affect the operation of other equipment.

4.4

Electromagnetic Compatibility (EMC) In order to comply with the requirements of IEC 61000, all electrical equipment shall meet the current applicable levels of ‘emission’ and ‘immunity’. All applicable equipment shall be designed so that the electromagnetic disturbance it generates does not produce a level which would prevent telecommunications equipment and other relevant apparatus from operating as intended. The design of equipment should be of an adequate standard to maintain its performance during its operational life in its installed environment. For the purpose of EMC, the performance of apparatus that must comply is taken to be degraded if permanent or temporary loss of function occurs.

4.5

Ingress Protection All field mounted equipment, including entries and blanking plugs, shall have an ingress protection to IP56 or more severe (protected against dust and strong jets of water) to IEC 60529. Instruments not classified accordingly shall be subject to Purchaser approval.

4.6

Utilities The following utilities can be made available, as required, at the control valves : • Uninterruptable power supply (UPS) for instruments - for Solenoid Valve

24Vdc

- for Electro-hydraulic actuator

230Vac single phase

• Instrument air - Design pressure

11.0 barg

- Normal pressure

7.5 barg

- Minimum pressure

6.0 barg

- Dew Point

Minus 10 degC @ 8 barA

Pneumatic actuators shall be sized on the basis of a minimum air pressure of 4.0 barg.

Where applicable, limit switches will be required to switch 24 Vdc signals from remote panels or equipment cubicles. Valve positioners and position transmitters shall be ‘two-wire’ type with loop power derived from remote panels or equipment cubicles.

4.7

Process Data The majority of control valves will be used in piping systems containing hydrocarbon liquid or gas. Specific process data for each control valve shall be referred to the Data Sheets.

4.8

Control Valve Sizing and Characteristics Control valve sizing coefficients shall be calculated in accordance with ANSI/ISA S75.01, Control Valve Sizing Equations. The calculated Cv at normal flow conditions shall not exceed 60 % of the selected valve capacity (85 % travel on equal percentage trim). The calculated Cv at maximum flow conditions shall not exceed 85 % of the selected valve capacity (95 % travel on

equal percentage trim). The calculated Cv at minimum flow conditions shall not be less than 10 % of the selected valve travel (3 % capacity on equal percentage trim). In cases where over 50% of the process system pressure drop is taken across the valve, a linear characteristic should be used. In all other cases an equal percentage characteristic is preferred. 4.9

Noise The maximum predicted noise level for control valves shall not exceed 85 dbA at 1 metre from the valve.

4.10 Stroking Times Control valve stroking time shall be a maximum of 20 seconds unless otherwise noted. 4.11 Calculations The Supplier shall include in his Proposal the following calculations based on the Process Data provided in the Data Sheets : • Control valve sizing at all stated flow conditions. • Noise levels at all flow conditions. The Supplier shall call the Purchaser’s attention to any inadequacies or inconsistencies in the information provided in the Data Sheets or the Requisition. 4.12 Maintainability Equipment requiring routine maintenance, testing and adjustment shall be readily accessible and easy to remove in order to minimise operating costs. It shall be possible to perform these operations, with the valves installed, under all weather conditions. Heavy equipment shall include provision for the fitting of eye bolts to facilitate mechanised lifting. All equipment, materials, components and fittings shall be designed for minimum maintenance over the required design life of 25 years. 4.13 Hazardous Area Requirements The process area is generally classified as Zone 2 with some areas Zone 1. The gas group is IIA and temperature classification T3. Instrumentation installed in the process area shall be in accordance with the IEC 60079 series (Electrical Apparatus for Explosive Gas Atmospheres) as listed in Section 2.1.

The minimum requirement is that instrumentation shall be suitable for Zone 1, gas group IIA, temperature classification T3. In general, electrical equipment in hazardous areas shall be certified flameproof, (EEx‘d’). Where suitable EEx‘d’ equipment is not available, consideration will be given to the use of intrinsically safe (EEx’i’) equipment. If EEx’i’ equipment is selected, galvanic isolators (rather than Zener barriers with dedicated IS earth bars) shall be used. All hazardous area equipment certification shall take account of the high ambient temperatures as specified in Table 4.1. 5. Equipment requirements 5.1

Valve Construction Construction of control valves shall comply with the following general requirements : • Control valves shall normally be of the globe type. They may be fitted with cage trim, single seated trim with plug or stem guiding, or double seated trim which should be top and bottom guided. • Control valve bodies shall generally be flanged except for butterfly valves (if applicable) where consideration will be given to the use of wafer style valves. Control valve bodies shall be flanged for all hydrocarbon duties. • Control valve bodies shall be cast. Casting repair by welding, etc, will not be allowed. When the Supplier prefers to apply forging, it shall be clearly stated in his proposal. • Control valve body size shall generally be selected on the basis of a maximum velocity at the inlet flange of 5 m/s for liquids and 0.3 mach for gases. • The minimum control valve body size shall be 1” nb. • Intermediate valve body sizes of 2½” and 5” nb shall not be used.

5.2

Control Valve Actuators Construction of control valve actuators shall comply with the following general requirements : • Actuators at the CPF(Central Processing Facility) shall be pneumatic, either diaphragm or cylinder type. The action on air failure shall be as defined on the Data Sheets. • Actuators at the satellite stations shall be integral electro-hydraulic type.

• Valve actuators shall be sized to close the valve against the maximum differential pressure specified on the Data Sheets. • For Instrument air or hydraulic supply, Instrument valves and fittings shall be stainless steel with double ferrule compression ends. Instrument tubing shall be 316 stainless steel. All instrument tubing and fittings shall be in Imperial sizes, with a minimum size of 3/8” OD. • One air supply connection shall be provided for the valve assembly for Purchaser’s field construction work. Size of the connection shall be adequately designed by Supplier for the total air consumption. • Electro-hydraulic actuator shall preferably be pre-assembled at factory as an complete actuator and no internal tubing/wiring work at site is required. 5.3

Materials Materials of construction shall be suitable for the environmental conditions specified in Table 4.1 and the process conditions specified in the Data Sheets. Materials of construction of in-line equipment shall be equal to or better than as specified on the Data Sheets for Control Valves. Valve trim shall be a minimum of 316 stainless steel unless process conditions necessitate alternative materials. Stellite or equal trim shall be provided on liquid service or where the operating pressure drop is in excess of 14 bar. Tungsten carbide trim shall be used for all services where erosion may be considered. Soft seats may be used due to leakage class requirement if process conditions permit. Valve packing shall be Teflon V-ring for duties up to 230°C and high density graphite or equal for duties above 230°C unless the Supplier recommends a higher grade or if the materials listed are not compatible with the process fluid. Actuator bodies shall be in painted or suitably protected carbon steel. Field mounted instrument items (e.g. E/P positioners, air filter regulators, solenoid valves, etc.) shall generally be stainless steel. Aluminium or aluminium alloys shall not be used unless an alternative material is acceptable. In these instances, the items shall be provided with a coating suitable for the environment.

5.4

Flange Ratings Inlet and outlet flange ratings shall be as identified in the Data Sheets. The minimum inlet flange rating shall be ANSI 300. Flanges with a rating of ANSI 600 or above shall be Ring Type Joint (RTJ), and flanges with a rating of ANSI 300 shall be Raised Face (RF). Pressure/Temperature rating of flanged components shall be as follows: For class 300,600,900 and 1500 ASME B16.5 : For 1” through 24” For class 2500 ASME B16.5 API 6A(10000 rated working pressure)

: For 1” through 12” : 14” and over

For class 4500 API 6A(10000 rated working pressure)

: For 1” through 24”

Gasket contact surface shall be in accordance with ASME B16.5 para 6.4. 5.5

Ancillary Equipment Pneumatically actuated control valve/actuator assemblies shall be provided with air filter regulators and Electro-pneumatic positioners. Electro-pneumatic positioners with gauges for signal input, signal output and air supply shall generally be provided. Electro-hydraulic actuated control valve/actuator assemblies shall be provided with Electro-hydraulic positioners and necessary ancillary equipment for hydraulic actuator. A stem position indicator shall be provided for all control valves. Where specified on the Data Sheets, the Supplier shall also include for the supply of additional ancillary equipment, e.g. solenoid valves, limit switches or position transmitters. Where specified, solenoid valves shall be heavy duty, certified EEx’d’ with 24 Vdc coils. Limit switches shall be proximity type or microswitch type with noble metal contacts suitable for low current, 24 Vdc signals. All instrumentation with electrical connections shall have ISO M20 threaded cable entries using a junction box if necessary.

5.6

Labels Each control valve shall be provided with a manufacturer’s data plate showing the following : • Valve and ancillary tag numbers. • Manufacturer. • Model number. • Serial number. • Failure action. • Body size. • Valve Cv. • Flange rating. • Materials of construction. • Hazardous area certification (where applicable). Any descriptive data shall be in the French language. a stainless steel label engraved with the valve (or ancillary) tag number shall be permanently attached to the relevant item. In addition, the valve tag number shall be clearly marked on the assembly, in a prominent location, using 2 cm high characters.

5.7

Painting Painting procedures shall reflect the harsh desert environment in which the equipment shall be installed. All external metallic surfaces, other than stainless steel, shall be coated in accordance with the Standard Specification for Coating, Painting and Galvanising, 7461-ORH-SP-M-00011(S-000-13A0-001). However, the Supplier may offer his standard Painting Specification with his Proposal, for approval by the Purchaser, provided it is suitable for the environmental conditions identified in this Specification. Valve actuators shall be painted green. Valve bodies shall be painted silver.

6. Preparation for shipment 6.1

Cleaning and Preservation All control valve assemblies shall be suitably treated and cleaned. After cleaning and inspection is complete, all internal surfaces shall be preserved with

corrosion inhibitor and all openings sealed in accordance with the Project requirements. The Supplier shall provide a preservation procedure that will be subject to Purchaser’s acceptance. 6.2

Packing The equipment shall be packed for export shipment and storage as follows : • Control valve assemblies shall be wrapped in waterproof material and be placed in crates having an internal waterproofed lining and padding. • All equipment shall be protected from vibrations and shocks normally expected during handling, loading/unloading and shipment. • The packing shall also be suitable for storage of the equipment for up to 12 months in the harsh outdoor environment described in Section 4.2. The packing shall be adequate to resist the dust, heat and corrosion conditions to be expected in the site location. If necessary, the Supplier shall advise of any special storage conditions required for the equipment in his supply. • Transportation weight and size limitations shall be as defined in the Standard Specification for Site Environment, Utilities and Transportation.

6.3

Shipment The Supplier shall allow for the transport of the equipment to a nominated port in country of origin as defined in the Requisition.

7. TESTING AND COMMISSIONING 7.1

General After final assembly, the Supplier shall carry out his own comprehensive testing procedures to ensure full functionality of the complete system prior to offering the equipment for witnessed Factory Acceptance Test (FAT). The overall testing and commissioning procedure is envisaged to be in at least three stages as follows : • Supplier’s tests. • Witnessed FAT (including FATs at sub-contracted suppliers’ works as appropriate), with Purchaser and Third Party present, to demonstrate functionality of the equipment and system using simulated inputs. The FAT procedures are subject to Purchaser and Third Party review and approval before the three weeks’ notice of test.

• Site commissioning to demonstrate full functionality of the control valves following installation. The Supplier should note that the Purchaser and Third Party require three weeks’ notice for attendance at witnessed tests. The scope of the tests shall fully demonstrate the capability of the control valves to meet the requirements of statutory Regulations and this Specification. 7.2

Test Procedures Full test procedures shall be developed by the Supplier and provided for Purchaser/Third Party comment/approval, prior to the three weeks’ notice of factory and site tests.

7.3

Test Equipment All test equipment used shall have a current calibration certificate provided by an accredited test facility and calibration shall be traceable to International Standards.

8. Documentation 8.1

General The Supplier shall include for an engineering documentation package in accordance with the Supplier’s Documentation Requirements Schedule (SDRS) incorporated in the Technical Requisition. Where practicable, documentation shall be provided in electronic as well as hard copy format.

8.2

Post-Order Documentation Following order placement, the Supplier shall provide documentation in accordance with the SDRS. Updated, Project specific versions of all documents provided with the Proposal and as identified in Section 8.2 shall be re-issued following Order placement. A full test procedure, including all inspection and test activities as required by the Certifying Authorities, shall be supplied and agreed prior to any acceptance testing. A design manual complete with all certification, inspection and works test documents, and certified copies of “As Built” drawings shall be provided for the Purchaser’s use when witnessing the final works testing and inspection. At an early stage of the Project, the Supplier shall provide a documentation schedule

listing all documents to be provided with anticipated issue dates. This schedule shall be updated as an ongoing activity throughout the Project until the FAT.