Invitation for Bids (IFB) Cairo/Egypt Project: South Helwan Project Savings

Transcription

1 Invitation for Bids (IFB) Cairo/Egypt Project: South Helwan Project Savings ICB No: GASCO/ICB/007 LOT 1: Ball Valves, Small Ball Valves & Related Services. LOT 2: Plug Valves and Related Services. LOT 3: Electrical Materials. LOT 4: Cathodic Protection Materials. LOT 5: Stainless Steel Fittings, Pressure Transmitters, Gauges / Scada Equipment and its Related Services 1. This Invitation for Bids follows the General Procurement Notice for this Project that appeared in UN Development Business Online. 2. The government of Egypt has applied for a loan from the International Bank For Reconstruction & Development toward the cost of South Helwan Project savings, and it intends to apply part of the proceeds of this loan to payments under the related contracts, noting that the loan is valid until the end of June 2019 and after that date, the said loan will be terminated and Gasco will not be able to pay any dues, if any. 3. The Egyptian Natural Gas Company (GASCO) now invites sealed bids from eligible and qualified bidders for: Serial Description Bidding Due Date Tender Fees LOT 1 LOT 2 LOT 3 LOT 4 LOT 5 Supplying Ball Valves, Small Ball Valves & Related Services Supplying Plug Valves and Related Services Supplying Materials Electrical Supplying Cathodic Protection Materials Supplying Stainless Steel Fittings, Pressure Transmitters, Gauges / Scada Equipment and its Related Services April 1 st, 2018 $ 1,000.00

2 4.Bidding process will be conducted through the International Competitive Bidding (ICB) procedures specified in the World Bank s Guidelines: Procurement under IBRD Loans and IDA Credits, and is open to all bidders from Eligible Source Countries as defined in the Guidelines. 5. Interested eligible bidders may obtain further information from Egyptian Natural Gas Company (GASCO) Materials General Manager/ Eng. Hazem Lotfy hazem_lotfy@gasco.com.eg moemen_mounir@gasco.com.eg moh_atef@gasco.com.eg ahmed_abdelaziz@gasco.com.eg Room No. :C227 N.B.: A complete set of Technical Specifications and Bill of Materials will be available at for review only. 6. A pre-bid meeting will be held with bidders at GASCO HQ, 10 A.M. Cairo Local Time on Monday 19/3/2018, to clarify technical and commercial issues. 7. A complete set of Bidding Documents in English may be purchased by interested bidders on the submission of a written application to the address below and upon payment of a nonrefundable fee equivalent to (USD 1,000.00). The method of payment will be Cash or direct deposit to: Gasco Bank Details Bank name : National Bank of Egypt (NBE) Branch : Main Swift code : NBEGEGCX001 For USD A/C NO. : For Euro A/C NO. : Accordingly, The bidding documents will be sent by to the concerned bidder. 8. Bids must be delivered to the address below at or before (10 A.M Cairo Local Time of April 1 st, 2018). Electronic bidding will not be permitted. Late bids will be rejected. Bids will be opened in the presence of the bidders representatives who choose to attend in person at the address below at (10 A.M on April 1 st, 2018). All bids must be accompanied by a Bid Security Bank Guarantee equivalent of: Lot 1, an equivalent of: $ 15, Lot 2, an equivalent of: $ 4,000.00

3 Lot 3, an equivalent of: $ 3, Lot 4, an equivalent of: $ 1, Lot 5, an equivalent of: $ 6, The address referred to above is: Egyptian Natural Gas Company (GASCO) The Ring Road, El Teseen St., 5 th Settlement New Cairo Eng. Hazem Lotfy /Room No. :C227 City Code: +202 Phone E Mail: hazem_lotfy@gasco.com.eg moemen_mounir@gasco.com.eg moh_atef@gasco.com.eg ahmed_abdelaziz@gasco.com.eg

4 GENERAL SPECIFICATION FOR FORGED STEEL BALL VALVES General Specification for Forged Steel Ball Valves Specs. No. GASCO / MS / 009 Rev. 10 Issue: Nov No. of Sheets: 27

5 Ball Valves Specs. No. / MS / 009 Rev. 10 CONTENTS Method of Offer Presentation 1. Scope. 2. General Service Conditions. 3. Materials. 4. Design and Construction. 5. Testing. 6. Inspection. 7. Data & Drawings. 8. General / Service Condition. 9. Specification of Gas over Oil Actuator. 10. Important Notes. 12. Specification Table. - Quality procedure - Painting specification for Aboveground & Underground facilities - Gas over oil actuator data sheet Attachment: Gas over oil actuator schematic diagram (one page). Page 1 of 27

6 Ball Valves Specs. No. / MS / 009 Rev. 10 SPECIFICATION OF FORGED STEEL BALL VALVES 1. SCOPE 1.1 All valves shall comply with the requirements of ASME B 31.8, Latest Edition, Gas Transmission and Distribution Piping Systems. 1.2 All valves shall be full bore and permit the safe passage of all pipeline pigs. 1.3 Valves shall be made in accordance with API 6D Specification for Pipeline Valves, Latest Edition, and with the requirements of this Specification. 2. GENERAL SERVICE CONDITIONS 2.1 Fluid Medium : natural gas 2.2 Ambient temperature : -5 C to + 50 C 2.3 Operating Temperature : Minimum - 5 o C Maximum + 70 o C 2.4 Pipeline operating pressure : Minimum 25 bar Maximum 70 bar 2.5 Pipeline Design pressure : 77 bar 2.6 Valves may be installed: Above ground unsheltered Below ground with or without extensions as required. 2.7 Valve stem may be positioned Vertically Horizontally 3. MATERIALS 3.1 Material for body shall be forged steel or rolled plates according to API 6D. Cast body is not accepted. 3.2 Material selected for the ball is forged steel with nickel plating. Minimum thickness of nickel plating to be 0.02 mm, and minimum specified hardness of coating to be 500HV. Cast ball is not accepted. Page 2 of 27

7 Ball Valves Specs. No. / MS / 009 Rev. 10 SPECIFICATION OF FORGED STEEL BALL VALVES 1. SCOPE 1.1 All valves shall comply with the requirements of ASME B 31.8, Latest Edition, Gas Transmission and Distribution Piping Systems. 1.2 All valves shall be full bore and permit the safe passage of all pipeline pigs. 1.3 Valves shall be made in accordance with API 6D Specification for Pipeline Valves, Latest Edition, and with the requirements of this Specification. 2. GENERAL SERVICE CONDITIONS 2.1 Fluid Medium : natural gas 2.2 Ambient temperature : -5 C to + 50 C 2.3 Operating Temperature : Minimum - 5 o C Maximum + 70 o C 2.4 Pipeline operating pressure : Minimum 25 bar Maximum 70 bar 2.5 Pipeline Design pressure : 77 bar 2.6 Valves may be installed: Above ground unsheltered Below ground with or without extensions as required. 2.7 Valve stem may be positioned Vertically Horizontally 3. MATERIALS 3.1 Material for body shall be forged steel or rolled plates according to API 6D. Cast body is not accepted. 3.2 Material selected for the ball is forged steel with nickel plating. Minimum thickness of nickel plating to be 0.02 mm, and minimum specified hardness of coating to be 500HV. Cast ball is not accepted. Page 2 of 27

8 Ball Valves Specs. No. / MS / 009 Rev Material selected to valve stem shall be forged steel with electro nickel plating or stainless steel material. 3.4 Material selected for welding end shall have a guaranteed minimum yield strength suitable for direct attachment to pipe according to API 5L as per table of requirements. Any differences in the Specified Minimum Yield Strength "SMYS", for both weld ends and pipes, shall be taken into account when calculating wall thicknesses at weld ends. In addition, the inner diameter of the weld ends of the ball valve and the pipe shall be the same. 3.5 Material selected for valve welding ends and pup pieces (if exist) shall have a maximum carbon equivalent of 0.42 % determined by the formula. CE = C + Mn + cr + Mo + V + Ni + Cu Charpy impact testing Where welding is carried out on pressure containing parts of valves at thickness greater than 25mm, post weld stress relief must be carried out. Charpy impact testing is required on the material of the pressure containing parts, including welding ends, according to ASTM 370. Charpy specimens shall be taken in the direction of principal grain flow, and notched Fperpendicular to the original surface of the plate or forging. Tests shall be carried out at -10 o C. The method of testing shall be in accordance with BS 131 : Part2. Acceptance standards are given in table 4. Table 1 - Acceptance standards for valve end material Specified tensile strength for valve end material Less than 450 N/mm N/mm 2 and above Average of three full size specimens (minimum) (J) Individual full size specimens (minimum) (J) DESIGN AND CONSTRUCTION 4.1 The design and construction of valves shall comply with the requirements of API standard 6D, latest edition, ASME B 31.8 & ASME B For one piece body valves. 4.2 Welding ends shall be beveled for welding to pipe or fittings in accordance with ASME B Page 3 of 27

9 Ball Valves Specs. No. / MS / 009 Rev Due consideration of difference in Specified Minimum Yield Strength "SMYS" (for both valve ends and pipes) shall be taken when calculating wall thickness at welding ends. 4.4 The ball shall be solid ball, one piece without welds. 4.5 For sizes up to and including 24". Valve flange dimensions shall be in accordance with ANSI B16.5 latest edition. For sizes 22" and above 24" valve flange dimensions shall be in accordance with MSS SP If required, pups shall be manufactured according to API 5L with the same wall thickness as specified in table of requirements. The minimum pup lengths will be equal to (one D up to 75cm) for all diameters 8" and 20 cm for smaller diameters. 4.7 The length of the valve with pup shall be equal to the length of valve according to API 6D (short pattern is not accepted) plus to the length of the 2 pups as per For ball valve greater than 36", API 6D and ASME B16.10 don't cover the valve face to face dimensions, so the minimum acceptable length of that dimension is 2083mm. 4.8 All valves shall have the following: The valve body shall be provided with ribs or feet to support the valve in the vertical position The valve shall be trunnion mounted Stem protectors and indicator rods shall be provided when so specified The valve should be one piece body full bore or reduced bore as per table of requirements. A bolted body is not accepted The ball shall be solid and one piece without any weld a The valves must be double piston effect seat design The ball valve should be double block and bleed. A trunnion seal arrangement shall be provided with a double block with vent/drain facility. The body of the valve shall have adequate full bore body vent and drain valves to fully vent/drain the cavity of the ball. The body vent and drain valves shall be of a low maintenance type supplied complete with plugs. These connections must offer a gas tight seal and must conform to ANSI B18.1 Standard for thread type drain/vent connections. Ball Valve Sizes Drain/Vent Connections 6" to 14" 1/2" 16" to 22" 3/4" 24" to 34" 1" 36" to 48" 1.5" Page 4 of 27

10 Ball Valves Specs. No. / MS / 009 Rev Sealant injection points on ball valves shall be provided. These injection points shall incorporate non-return valves in the valve body followed by an isolating valve and a giant button head nipple of ample capacity for injecting sealant. Injection points for the stem seal shall also be provided The valves shall be fire safe according to British Standard and API Standards. These Standards to include API 6FA, API 607, as per clause A6 in API 6D, and BS 6755 Part 2. Where standards conflict, the worse case shall be adopted and confirmed by return tender document. This must include a fire safe graphite stem seal Three hand guns with quantity (60) sealant sticks are required with the order at no extra cost for the quantity All welding shall be in accordance with the requirement of ASME Boiler and Pressure Vessel Code, latest edition, Sections VIII and IX The stem seal shall be replaceable while the line is in operation in open or closed position Gear operated valves shall have worm gear type with the hand wheel on the side. The gear housing must be water tight. All moving parts should be grease filled. The diameter of the hand wheel or the length of the operating lever shall be such that the total force required to operate the valve throughout its full operating range shall not exceed 350N. The direction of operation (clockwise to close) of the hand wheel or lever shall be clearly marked. When the hand wheel or lever itself carries this marking it shall be non-reversible on the valve stem. Means shall also be provided on the gear box, where supplied, to show the position of the valve throughout its travel. All gear box cases shall be provided with a relief valve to prevent overpressurization in the event of gland leakage, unless the design of the valve is such that it is not possible to occur. Blow out plugs shall not be permitted All valves shall be fitted with suitable stops at the fully closed and fully open positions and shall be so designed as to prevent disorientation. The design shall prevent the ingress of foreign material and corrosion products that could impair the operation of the stops A device capable of locking the valve in the fully open or fully closed position shall be provided The inner diameter of the valve shall be as stated in table of requirements All valves and stem extension shall be painted with 2 pack epoxy urethane according to the attached specifications. Annex B. Page 5 of 27

11 Ball Valves Specs. No. / MS / 009 Rev REQUIREMENTS FOR STEM EXTENSION ASSEMBLIES Where provision is made for mounting a stem extension assembly, the closing shall be such that the complete assembly will form a rigid unit giving a positive drive under all conditions with no possibility of free movement between the valve body stem extension or its operator The inner drive stem extension shall be so designed as to ensure that full engagement with the valve stem is maintained in all attitudes of the valve and stem extension assembly Where a hollow valve stem extension (i.e. inner drive stem extension) is used, provision shall be made to equalize the pressure between the bore of the stem extension and the annulus. To prevent ingress of water, the necessary vent hole in the inner hollow stem extension shall be drilled above the level of any vent in the outer stem extension tube The outer housing shall be fitted with a vent to atmosphere incorporating a relief valve set at 0.5 bar, to prevent pressure build up. Blow out plugs are not permitted The supply of a stem extension assembly shall include gaskets for both upper and lower mating flanges. To prevent the ingress of water, these gaskets shall be suitable to resist an external pressure of 1 bar The supply of the stem extension assembly shall include extensions to the vent and sealant connections. Separate extension lines shall be provided for each sealant injection point. The pipe used shall conform to API 5L, grade B, schedule 80, sized not less than the connection size in the main valve body Vent, drain and sealant lines shall either be butt welded or socket welded in construction, except that the sealant lines may incorporate a breakaway coupling where necessary for assembly purposes and threaded connections may be used for sealant valves. The connections into the valve shall be threaded or socket welded. Where socket welding is required and specified, the connection into the valve shall be by means of a purpose made fitting. The fitting shall incorporate a tapped hole, as per 4.8.7, to permit a screwed plug to be used to blank off any unused tapings. Screwed connections shall not be seal welded Socket weld fittings for vent and drain lines shall be to b as a minimum rating Vent drain and sealant line extensions shall be fitted with valves of nominal size equal to the connection size in the main valve. Two valves shall be provided, one Page 6 of 27

12 Ball Valves Specs. No. / MS / 009 Rev. 10 immediately adjacent to the valve body and one adjacent to the upper flange of the stem extension. The top of the vent and drain lines shall be clearly marked to indicate which is vent and which is the drain. the The vent, drain and sealant lines shall be provided by the contractor The vent, drain and sealant lines shall be adequately supported from the outer extension tube, which should not be drilled to provide such support. The design of the supports shall be such that operations of the valve, or discharge of gas will not impose excessive forces on the pipe work A stem extension should be assembled with the valve and should not be separated from the valve for dispatch to site. 5. TESTING 5.1 The following tests shall be performed on the material of pressure containing parts and welding ends : a) Charpy impact test according to item 3.5 of this specification b) Mechanical tests as per API 6D c) Chemical test as per API 6D 5.2 All valves shall be subjected to a shell hydrostatic pressure test in accordance with API 6D requirements as per Annex A attached. The supplier to submit test procedures for approval for all tests required. The supplier to provide torque-testing figures of the valve/operator as described in API 6D Appendix C. C4, to ensure that the operation of the valve/operator is within specified limits. 5.3 Hydrostatic seat test shall be carried out as required by API 6D and Annex A attached. While the test pressure is on each side of the valve. It shall be operated at least twice to demonstrate satisfactory mechanical operation as well as continuous tightness after operation. 5.4 Valve shall be subjected to air seat test in accordance with API STD 6D requirements and Annex A attached. If a double block and bleed check is provided the valve body to be vented to check satisfactory sealing of the valve seats. Where valves are actuated, the valve and actuator are to be tested together, to prove the function of both valve and actuator. Where valves incorporate stem extension assemblies, vent and sealant extensions Page 7 of 27

13 Ball Valves Specs. No. / MS / 009 Rev. 10 must also be included. These are to be tested to the relevant seat pressure with the valve closed to check efficiency of closing weld. The supplier should give GASCO the opportunity to witness all the tests of all pupped valves after the pups are welded on. Where valves are supplied without pups, the valve manufacturer must issue a weld procedure to GASCO for this work to be carried out on site. 5.5 The valve manufacture shall give sufficient advance notice in writing satisfactory to the company of the time and place at which hydrostatic and pneumatic testing is to be performed. 5.6 Operational torque test according to API 6D Appendix C. 5.7 Test certificates shall be submitted for verification. 6 INSPECTION 6.1 All body welds, pressure containing parts and seat ring areas shall be inspected 100% by ultrasonic or radiographic examination. Welds joining all non pressure containing parts of valves and gear boxes shall be subject to random 10% M.P.I. crack detection. Lifting lugs or brackets welded to valve bodies shall be subject to 100% M.P.I. Test certificates should detail all testing completed during manufacture of the valve. This should include a certificate of conformity with a unique identification number. 6.2 All welding ends of valves shall be checked by magnetic particle inspection. Test certificates shall be provided for verification. 6.3 Handling and Transport All precautions should be taken to avoid contamination of seats and seating components. During transit valves must be supported. If chains/wire ropes are used to secure valves, they shall not come into contact with the valve or pup. Any damage will be cause for rejection. Ends of valves shall be fitted with a protective cap to prevent any damage. The ends shall be sealed to prevent ingress of dirt or moisture. Ball valves shall be transported fully open. Page 8 of 27

14 Ball Valves Specs. No. / MS / 009 Rev Marking The information required to identify the valve shall be generally as specified in the relevant standards (see.4.0) with the items listed below: a) Manufacturer's Name b) Valve size c) Serial number d) Rating e) Maximum operating pressure f) Test pressure g) Design temperature - minimum & maximum h) Valve body material i) Ball, stem and seat ring material j) Wall thickness of weld ends k) Gross weight of assembled valve (Kg) l) Valve operator and its manufacturer. Valve, valve actuator, gearbox and stem extension shall be separately marked and identified. Note: Marking requirements should be clearly stated on the name plate attached to the valve 7 DATA AND DRAWINGS 7.1 The manufacturer shall provide the following information Outline dimensions and mechanical details for the valve Number of complete revolutions the wheel or other operating device to close or open the valve and torque required The maximum permissible torque and the rated torque required closing or opening the valve at the maximum pressure differential Head loss curve and data for the valve The offer shall include details of tests The offer shall include the certificate of ISO 9001, API 6D, and fire safe certificate. The offer will not be accepted in case of any of these certificates are not included The Data Sheet shall include the details of the stops and locking device. Page 9 of 27

15 Ball Valves Specs. No. / MS / 009 Rev GENERAL / SERVICE CONDITION -Pipeline axis and diameter -Pipeline length -Distance between valves -Medium Natural gas -Valve stem Vertical/Horizontal -Drive power supply for actuator direct from pipeline -Pipeline design flow rates and pressure Flow rates Pressure -Pipeline design flow rates and pressure for actuator operation: Flow rates (Max./Min.) Pressure (Max./Min.) -Maximum operating temperature +70 C Minimum operating temperature - 5 C Ambient temperature +5 to +50 C Page 10 of 27

16 Ball Valves Specs. No. / MS / 009 Rev SPECIFICATION OF GAS OVER OIL ACTUATOR 9.1 General All offered equipment should be suitable to work in a sandy desert and marine environment Selected actuator type's catalogue should be submitted showing all actuator accessories All electrical equipment should be explosion proof to EEx-d-IIC-T5-IP67and 24 V D.C Actuator torque table should be submitted All vent to atmosphere via 3 meters' high vent pipe Reference list should be attached to the technical offer Attached table of specifications should be completely filled, stamped and attached to the technical offer All equipment should be suitable to high pressure execution in accordance to the pipeline design pressure Any deviation from this specification should be highlighted in a separate section inside the technical offer All pneumatic tubing and fittings should be 316 stainless steel in accordance with the maximum pipeline design pressure All hydraulic tubing and fittings should be 316 stainless steel in accordance with the maximum pipeline design pressure Operating temperature -5 to +70 C Ambient temperature -5 to +50 C. 9.2 Hydraulic cylinder Totally enclosed weatherproof carbon steel housing Scotch yoke mechanism with chromium plated guide bar and piston. 9.3 Gas over oil tanks Two gas over oil tanks according to ASME VIII div Complete with unidirectional flow control valve for speed adjustment Oil filter and oil dip stick. 9.4 Hydraulic manual override Hydraulic hand pump Manual directional valve. 9.5 Actuator safety factor Actuator minimum safety factor is 125%. Page 11 of 27

17 Ball Valves Specs. No. / MS / 009 Rev Emergency gas storage tank Emergency gas storage tank should be sized for a minimum of four strokes ( 2 open + 2 close) in case of power supply failure Operating pressure in accordance with the maximum pipeline design pressure Complete with Isolation valve, Check valve, Relief valve and Pressure Gauge + isolation valve. 9.7 Limit switches Two limit switches (open / close) in an explosion proof box to -IP Each limit switch contains two DPDT mechanical contacts One contact will be used for indication and the other contact will be used for solenoid valve permission Local visual mechanical indicator. 9.8 Gas power supply Complete with high pressure shuttle valve, two isolation valves, dehydrated filter with condensate separator and non return valve. 9.9 Control system Control panel accessories should be sized for a maximum operating time of 3 seconds for inch valve size All control system components should be fitted inside a totally enclosed weatherproof carbon steel enclosure complete with vent valve Complete with two 24 VD.C. explosion proof solenoid valves (open / close) with manual override in compliance with EEx-d-IIC-T Complete with pneumatic pilot operated valve with hand (push) spring return Complete with Local / Remote valve All internal wiring between or inside junction boxes should be included in the Supply All required cable glands for inlet and outlet cables should be explosion proof and included in the supply Compatibility between valve and actuator The manufacturer of the actuator, if different from the valve manufacturer, shall arrange with the valve manufacture on the fitness of the actuator including the gearing for use with the valve. Prior to the commencement of the fabrication of the actuator, the manufacturer of the actuator shall supply design drawings of the actuator to the valve manufacturer which shall submit said drawings to GASCO for approval Functional requirements When a remote control command is given, the main valve shall close. Page 12 of 27

18 Ball Valves Specs. No. / MS / 009 Rev After closing the main valve by remote control command, the main valve shall only be opened by local manual operation In case of electrical or pneumatic power supply failure the main valve shall not close, it shall stay in existing position Documentation The following documentation should be submitted as minimum requirements Complete catalogue including all actuator accessories Overall dimensional drawings Control schematic Wiring diagram Explosion proof certificates Actuator factory acceptance test certificate Operation and maintenance manual Spare parts list Actuator data sheet Actuator / Valve performance Data sheet The following data sheet contains minimum information required and shall be completed by the contractor/manufacturer for every identical type and size of the actuator and ball valves. Page 13 of 27

19 Ball Valves Specs. No. / MS / 009 Rev Data sheet - Gas Over Oil Actuator 1 Data sheet no. 2 Object Gas Over Oil Actuator 3 Tag no. GO - * 4 Designation 5 Area code 6 Location module * 7 Run no. * 8 Manufacturer ** 9 Built year ** 10 Fabrication no. ** 11 Actuator type/model ** 12 Refer. Dwg. No. ** DESIGN DATA 13 Flow medium Natural gas 14 Valve size * inch 15 Gas analysis * 16 Valve press. Rating lb. 17 Environmental data * 18 Piping class No. 19 Valve specification Spec. no. 20 Act. design press. bar g 21 Piping specification Spec. no. 22 Act. oper. press. bar g 23 Actuator specification Spec. no. 24 Act. design temp. range C 25 Actuator design code ** 26 Ball valve fabr. no. 27 Actuator design ** Pneumatic / Manual 28 Ball valve tag no. 29 Service - Actuator * Above ground 30 Ball valve data sheet 31 Service - Ball valve * Above / Below ground 32 Quantity Each PERFORMANCE DATA 33 Actuator type ** 34 Gear start torque ** Nm 35 Actuator/Valve compatibility ** 36 Gear run torque ** Nm 37 Stem extension * 38 Max. output torque ** Nm 39 Remote control ** 40 Max. actuator torque ** Nm 41 Hand pump ** 42 Time to open valve ** sec. 43 Speed control ** 44 Time to close valve ** sec. 45 Supply *** 46 Gear manufacturer ** 47 Power *** 48 Gear type ** Clockwise / 49 Explosion proofing *** 50 Direction of rotation Anti clockwise 51 Degree of protection *** 52 Gear ratio ** Page 14 of 27

20 Ball Valves Specs. No. / MS / 009 Rev Data sheet - Gas Over Oil Actuator (Cont'd.) DIMENSIONS AND CONNECTIONS 53 Total L x B x H 54 Electrical connection *** in/mm Pneumatic 55 connection 56 Total weight ** Kg 57 Drain connection 58 Position indicator ** 59 Vent connection 60 Compat. Act. & BV ** Lubricant Exhaust 3 mt. to 61 injection 62 atmosphere ** MATERIAL, TESTS AND DOCUMENTATION 63 Gear material ** 64 Factory acceptance test (FAT) ** Hydraulic cylinder 65 material ** 66 Final acceptance by ** Gas cylinder 67 material ** 68 Actuator certification ** 69 Valve material ** 70 Equipment certification ** Connector material ** 72 Material certification ** Tubing material ** 74 Construction drawings ** 75 Electrical cables ** 76 Inspection drawings ** 77 Sealing material ** 78 Electrical drawings ** 79 Lubricant ** 80 Actuator documentation ** 81 Function test ** 82 Operating manual ** 83 Painting ** 84 Maintenance manual ** Factory 85 inspection ** 86 Spare parts list ** 87 Others inspection ** 88 QA documents ** REMARKS * GASCO / Contractor data and selection ** Manufacturer data and confirmation *** Optional manufacturer data Page 15 of 27

21 Ball Valves Specs. No. / MS / 009 Rev IMPORTANT NOTES: 10.1 Any exception to this specification shall be stated clearly in the offer If the manufacturer wishes to offer equivalent standards other than stated here in specifications, the equivalent specifications must be stated. Supporting documents and standards shall be submitted with the offer to prove the equivalent specification of each item Reference list is required to be attached with the offer The table of specifications attached here should be completely filled by the manufacturer and should be attached with the offer. If the offer is submitted without completion of these tables then the offer will be rejected The offer should include detailed latest edition catalogues which includes the offered types of ball valve with detailed dimensions, drawings, rates, sized...etc. Page 16 of 27

22 Ball Valves Specs. No. / MS / 009 Rev. 10 TABLE OF BALL VALVES SPECIFICATIONS CONFIRMATION INQUIRY NO. :... QUOTATION NO :... MANUFACTURE NAME :... CONFIRMATION OF REQUIREMENTS SPECIFICATION NOTES ITEM # ITEM # ITEM # ITEM # Design and Construction - Size (Inch) - Drawing Number - In case of issued "Purchase Order", Valve dimensional drawings related material part lists should be submitted for GASCO approval Before Valve Fabrication. - Rating Class ANSI (600) - Standard Code API 6D General Service Conditions - Fluid Medium: Natural gas - Ambient temperature: -5 C to + 50 ºC - Operating Temperature: Min./Max. -5/+70 ºC - Pipeline operating pressure: Min./Max. 25/70 bar - Pipeline Design pressure : 77 bar Ends Connections: - Butt Welding End acc. to ANSI B Flanged R.F. End acc. to ANSI B 16.5 (NPS 24") - Flanged R.F. End acc. to MSS SP44 (NPS>24") - Fully Welded Construction body (bolted body not accepted) - Full bore - Vent& drain ball valves acc. to item (4.8.6) - Sealant injection system acc. to item (4.8.7) - Double block and bleed - Double piston effect seat design - Trunnion mounted - Bi directional - Anti blow out stem - Anti-static design - One piece body without any bolted body joints. - Maximum operating temperature 70oC - Minimum operating temperature -5oC - Maximum working pressure (PSI) State the value - Stem seal is replaceable while line is in operation acc. to item (4.8.11) - The ball is solid one piece without any weld. For All Extended Stem Valves - Stem extension acc. to item (4.9) - Two valves shall be provided, one immediately adjacent to the valve body and one adjacent to the upper flange of the stem extension accordance with item (4.9.9). - Valves shall be supplied complete with a stem assembly together, actuator can be supplied separate. Dimensions - Face-to-face dimension acc. to API 6D (short pattern is not accepted) - Valve overall dimension shall be according to API 6D + 2 pup length, Page 17 of 27

23 Ball Valves Specs. No. / MS / 009 Rev. 10 SPECIFICATION - Stem Length measured from valve C.L. CONFIRMATION OF REQUIREMENTS ITEM # ITEM # ITEM # ITEM # NOTES TABLE OF BALL VALVES SPECIFICATIONS CONFIRMATION (Continue) SPECIFICATION CONFIRMATION OF REQUIREMENTS ITEM # ITEM # ITEM # ITEM # NOTES Operation - Unsheltered - Stem position vertical or horizontal - Wrench + lever - With actuator acc. to item (9) - Actuator and line break - Gear box as per item (item ) - The valve is suitable for sealing injection for ball and stem Materials - Body State the material - Ball State the material - Ball plating (nickel - chrome) State the material (Min. thickness 0.02 mm, Min hardness 500 HV) - Stem State the material - Primary and secondary seal for BALL State the material - Primary and secondary seal for STEM State the material - Seat ring (Min. thickness 0.02 mm) State the material Valve Welding Ends - Welding ends material should be suitable for welding to pipes of API 5L acc. to item (3.3) - Welding end material State material - Yield strength (PSI) State the value - Wall thick. (inch) acc. to item (4.3) of specs. State the value - Fracture toughness of welding ends as per item (3.6) Pup Pieces: - Pup Material State the value - Yield strength (PSI) State the value - Wall Thickness (inch) State the value - Pups Length State the value - Material selected for valve welding ends shall have a maximum carbon equivalent of 0.42 % acc. to item (3.4) - Material selected for pup pieces (if exist) shall have a maximum carbon equivalent of 0.42 % acc. to item (3.4) Painting (Valve & Actuator) - For above ground valve acc. to GASCO SPECS.-1 - For underground valve acc. to GASCO SPECS.-2 - Painting color RAL 7035 light gray FIRE SAFE TEST - Acc. to item (4.8.8) of specs API 6FA, API 607, and BS Fire safe graphite stem seal TESTING - Tests required on weld end and pressure containing parts material acc. to item (5.1) Page 18 of 27

24 Ball Valves Specs. No. / MS / 009 Rev The valve shall be tested with actuator and external stem if any acc. to item (5.4) - Shell hydrostatic test pressure in PSI acc. to item (5.2) of specs. State the value TABLE OF BALL VALVES SPECIFICATIONS CONFIRMATION (Continue) SPECIFICATION - Seat hydrostatic test pressure in PSI acc. to item (5.3) of specs. CONFIRMATION OF REQUIREMENTS ITEM # ITEM # ITEM # ITEM # NOTES State the value - Pneumatic air seat test acc. to item (5.4) of specs State the value - Hydrostatic test shall be complete with pup piece INSPECTION - Ultrasonic or radiographic examination for body's weld acc. to item (6.1) of specs. - M.P.I. for welding ends acc. to item (6.2) of specs. TEST AND INSPECTION CERTIFICATES - To be provided for approval Accessories required for all quantity : - 3 hand guns for sealant injection - Sealant sticks quantity (60) Inspection and Testing for Valves dates should be sent to GASCO before 45 days from the suggested dates. Note: Sign by ( ) for confirmed item and (X) for unconfirmed items. Important Notes 1. Materials selected for body should acc. to item (3.0) of specs and API 6D 2. All material should be stated in ASTM 3. Data and Drawings stated in item (7) of specs should be submitted with the offer. Acc. to = According to Wall thick. = Wall Thickness Specs = Specification R.F. = Raised Face R.T.J = Ring Type Joint 4. The vendor must submit table of confirmation completely filled and signed with the offer otherwise the offer will be cancelled. 5. Any technical deviation to line pipe specs. must be stated clearly. Production schedule must be submitted Valve weight for 2 ball valve shouldn t exceed 25 kg Page 19 of 27

25 Ball Valves Specs. No. / MS / 009 Rev. 10 TABLE OF GAS OIL ACTUATOR SPECIFICATIONS CONFIRMATION MANUFACTURE NAME :... SPECIFICATION CONFIRMATION YES NO Carbon steel housing, scotch yoke mechanism with chromium plated guide bar Hydraulic cylinder 2 gas oil tanks according to ASME V III div. 1 code with oil filters Gas filter and dehydrating cartridge. Pilot operated valve with hand (push) spring return operation facilities Control valve enclosure with vent valve Local mechanical position indicator Speed control valves Hand pump distributor for emergency operation Emergency gas storage tank sized for 4 stroke Pneumatic tubing and fittings 316 SS Hydraulic tubing and fitting 316 SS Exhaust vent 3m. high vent pipe Line connections, equipped with stop valves Type selected to be submitted with it's catalogue. Note: Sign by ( ) for confirmed item and (X) for unconfirmed items. Page 20 of 27

26 Ball Valves Specs. No. / MS / 009 Rev. 10 QUALITY PROCEDURE PRESSURE TESTING OF BALL VALVES 1. Scope This procedure applies to pressure testing all ball valves supplied to GASCO. Reference standard :- API Specification for Pipeline Valves API 6D 2. Valve Test Set up The valve is set up in the appropriate test fixture and with test flanges having suitable pressure connections. 3. Shell Test With the ball partly open the valve is filled completely with water, containing a rust inhibitor, via the body drain tapping 'D' (see Diagram 1). When full, valve 'D' is closed and hydrostatic pressure at the appropriate level (see Table 1 - Pressure and Duration Chart) is applied to the body shell via the body vent tapping 'B'. Pressure is observed by a gauge attached to the pressurising equipment, and if required, by a gauge and/or pressure recorder attached to either test flange (points 'X' or 'Y'). On reaching the required pressure, vent 'B' is closed and pressure maintained for specific periods as per Table 1. The valve is examined for leakage at closure to body joints, stem seals, gland plate to body joint and around any fitted plugs. No leakage permitted. The duration of the test is the period of time after the valve is fully prepared and under test pressure. 4. Seat Test (Hydrostatic) The purpose of this test is to demonstrate pressure tightness of the seat seals irrespective of the direction of flow. With the ball partly open the valve is filled completely with water. The ball is then fully closed against any operator travel stops and hydrostatic pressure at the appropriate level (see Table 1) is applied to one closure cavity via tapping 'A'. Page 21 of 27

27 Ball Valves Specs. No. / MS / 009 Rev. 10 Valves 'B' and 'C' are opened to atmosphere and water displaced by pressurisation will be released from point 'B'. On achieving the required pressure level valve 'B' is closed. Any leakage of water through the valve will show itself from valve 'C'. Alternatively, after allowing a few minutes for the valve to settle a glass sight tube may be attached to point 'C' and any change in fluid level monitored. The above procedure is then repeated for the other closure cavity using point 'C' in instead of point 'A' for pressurisation and pressure monitoring respectively. No leakage across the valve is permitted in either direction. The duration of test is the period of time after the valve is fully prepared and under test pressure. 5. Seat Test (Pneumatic) Having completed all hydrostatic testing the valve is blown down and drained of test fluid. The ball is fully closed against any operator travel stops. Valve 'B' is closed and Valve 'C' opened to atmosphere. Air at 14.51bs/sq.in (1 bar) is applied to one closure cavity via tapping 'A' and valve tested for leakage by application of soap solution at valve 'C'. At the same time leakage through any closure tapings are checked. The above procedure is then repeated for the other closure cavity using point 'C' in lieu of point 'A' for pressurisation and pressure monitoring respectively. The complete procedure is then repeated using air at 80lbs/sq.in. No leakage across the valve permitted in either direction. The duration of test is the period of time after the valve is fully prepared and under test pressure. 6. Actuator (functional) tests Valves fitted with power actuators (electric, hydraulic, pneumatic, gas/hydraulic) are subject to functional tests to demonstrate the capability of the actuator to operate the valve against specified conditions. The actuator to be operated to the closed position to demonstrate the valve is free from leakage. Test details vary according to type of actuator concerned but, in principle, the test consists of opening the valve against a differential hydrostatic pressure usually at a level corresponding to working pressure in service. Data recorded may include power parameters (electrical, pressure) noted during operation and operating time to cycle the valve. These figures are then compared with specific requirements and actuator specification. The functional test should also be repeated using the manual facility of the power actuator. Page 22 of 27

28 Ball Valves Specs. No. / MS / 009 Rev. 10 For valves operated manually by wrench or hand wheel through a gearbox, operating torque will be checked by means of a torque wrench applied direct to the valve stem (wrench operated) or to the gearbox input shaft. 7. Certificates A test certificate is issued for each valve showing type of test, pressure levels recorded, date of test and signature of person supervising the test as a minimum. 8. Alternative Pressure Tests The following is a list of alternative tests which can be offered. a) Direct upstream seat test (hydrostatic). As 4 above but checking for leakage at the body vent 'B'. b) Direct upstream seat test (Pneumatic). As 5 above but checking for leakage at the body vent 'A'. c) Direct downstream seat test (hydrostatic). Pressures in accordance with the table. Closure and body cavity tested simultaneously. Checking for leakage from downstream test fixture vent. d) On final inspection check both seats simultaneously as downstream seats by pressurising body cavity to 80lbs/sq in air with valve closed. Viewed directly into the bore. 9. Additional Tests Required a) Where valves are to be despatched with extended drain/vent pipe work fitted (screwed type). Check joint efficiency by pressurising pipe work to 80 lbs/sq in with valve closed after final assembly. b) Where valves are to be despatched with extended drain/vent pipe work fitted (welded type). Pre-assembled pipe work to be hydrostatically tested to relevant seat test pressure as shown in the table followed by a similar complete assembly hydrostatic test with valve closed to check efficiency of closing weld. c) Extended pipe work to be despatched for site fitting (welded type). Hydrostatic test of assembly to relevant body test pressure as shown in the table. Page 23 of 27

29 Ball Valves Specs. No. / MS / 009 Rev. 10 PRESSURE AND DURATION CHART EXTRACTS FROM A.P.I.6D TABLES 5.1 AND 5.2 Valve Class Valve Size inch inch 20 inch inch inch 20 inch inch inch 20 inch inch inch 20 inch inch inch 20 inch inch inch 20 inch + Shell Test Pressure Duration 425 lb/in 2 5 Min 15 Min 30 Min 1100 lb/in 2 5 Min 15 Min 30 Min 1450 lb/in 2 5 Min 15 Min 30 Min 2175 lb/in 2 5 Min 15 Min 30 Min 3250 lb/in 2 5 Min 15 Min 30 Min 5400 lb/in 2 5 Min 15 Min 30 Min Seat Test Pressure Duration 300 lb/in 2 5 Min 800 lb/in2 5 Min 1060 lb/in 2 5 Min 1600 lb/in 2 5 Min 2400 lb/in 2 5 Min 4000 lb/in 2 5 Min Page 24 of 27

30 Ball Valves Specs. No. / MS / 009 Rev. 10 SPEC. 1 Painting PAINTING SPECIFICATION FOR ABOVEGROUND FACILITIES * For pipes, valves, bends and other fittings. Paint cycle shall be as follows: Surface preparation : sa st Layer 2nd Layer 3rd Layer Total DFT Final Color : Zinc Epoxy, 1 coat DFT 75 µm. : High Built (HB) Epoxy 200 µm. : Polyurethane (PU) 50 µm. : 325 µm. : RAL 7035 Light Gray Page 25 of 27

31 Ball Valves Specs. No. / MS / 009 Rev. 10 SPEC. 2 Painting PAINTING SPECIFICATION FOR UNDERGROUND FACILITIES OPERATIONS CHART FOR 2-PACK EPOXY COATINGS Period before OPERATIONS Handling or next coating operation No. Description Min. Max. 1 Blast clean. 4h COMMENTS for Sa 2 1/2 (1S ) Profile micro 2 Clean all surfaces 2 24 To remove contamination Spray or Brush apply layer of coating material Moisture tolerant epoxy (Dry or moist surfaces) Apply further layers to give 2.5 mm. minimum thickness For moist or dry surfaces Surface must only be damp (i.e. no water droplets forming) Typical film thickness (wet or dry) 250 microns Use 2 colours of material. Alternate colour for each layer of coating and brush at right angles to previous layer. Final Color : RAL 7035 Light Gray Page 26 of 27

32 Ball Valves Specs. No. / MS / 009 Rev. 10 Page 27 of 27

33 GENERAL SPECIFICATION FOR SMALL BORE VALVES - NEEDLE VALVE - BALL VALVE - PLUG VALVE General Specification For Small Bore Valves Specs. No. / MS / 010 Rev. 3 Issue: Dec No. of Sheets: 6

34 Small Bore Valves Specs. No. / MS / 010 Rev. 2 CONTENTS Item no. Description Page No. 1. SCOPE GENERAL DESIGN DESIGN SAFETY MATERIALS VALVE HANDLES TESTS AND INSPECTION TABLE OF SMALL BORE VALVES SPECIFICATION CONFOMATION 6 Page 1 of 6

35 Small Bore Valves Specs. No. / MS / 010 Rev. 2 STANDARD FOR PIPE & FITTINGS SMALL BORE VALVES 1. SCOPE This specification specifies requirements for valves of nominal size 40mm and below for use with Natural Gas at pressures up to 100 bar and in the temperature range -20 to 150 o C, and includes valves of needle, ball and plug types. 2. GENERAL 2.1 Such valve requirements is generally covered under ANSI B 16.34, which includes instrument valves normally used as isolation valves to equipment/instrumentation or small bore piping system, either threaded, flanged or using compression couplings as specified in table of requirement. 2.2 All valves shall be designed to be capable of sealing against the rated pressure in both directions and passing Natural Gas in both directions irrespective of the preferred direction of flow. 2.3 Where carbon steel valves are used, the fittings and piping shall be compatible. 3. DESIGN 3.1 Needle Valves For general use, needle valves are sized up to 25mm, and shall be used for sensitive control, coupled with multiple turn operation Valves shall be of stainless steel body, spindle and connections Connections shall be either N.P.T. (Nominal Pipe Thread) screwed or compression couplings, either of the single ferrule or double ferrule type All compression coupling type valve ends shall be manufactured from austenitic stainless steel type For normal use a hard seat, soft tip combination is most suitable for durability. Alternatively where there is a degree of weld slag or other foreign matter entrained in the pipework system, then seat hard and tip hard combination should be considered. Page 2 of 6

36 Small Bore Valves Specs. No. / MS / 010 Rev Needle valve spindles may be either: - a) Two-piece non-rotating tip type or b) Rotating tip type. (See typical drawing) Threaded stem valves shall be designed to prevent binding or galling. 3.2 Ball Valves Design shall be of a "floating ball" assembly with 1/4 turn operation Preferable to be of split body design with N.P.T. screwed, socket-weld or flange connections Body may be of carbon steel or stainless steel material Ball & stem to be stainless steel material, or alternatively the carbon steel ball shall be Chrome or Nickel/Chrome plating or coating of not less than 0.03mm thickness, and of plating hardness of not less than 500 HB Valve to include for soft or hard body seals of acceptable material either side of the ball. 3.3 Plug Valves Lubricated plug valves shall be of the "balanced" type with 1/4 turn operation and to API Valve plug to be of carbon steel material with an acceptable corrosive resistant plating or coating of not less than 0.03mm thickness. Plating hardness shall be a minimum of 500HB Valve connections shall be N.P.T. screwed or flanged, flanges shall be to ANSI B Flanges shall be to ANSI B Primary seals shall include for suitable lubricant injection. Page 3 of 6

37 Small Bore Valves Specs. No. / MS / 010 Rev DESIGN SAFETY 4.1 Where pressure retaining parts or assemblies are held together by means of screwed components the valve shall be designed to prevent accidental disassembly under pressure. 4.2 Union type bonnets or screwed in gland assemblies shall be securely locked by an approved method. 4.3 Needle valves shall be provided with a back stop to prevent the needle spindle being unscrewed from the body. 5. MATERIALS 5.1 General For austenitic stainless steel valves designed with compression coupling type ends - either via a stud coupling being screwed in at time of manufacture or by integral casting/turning techniques - all parts of the end fitting (body, nut and ferrule) shall be manufactured from austenistic stainless steel to ASTM A 182/A a Grade F316. Ferrules to be Chrome plated. 5.2 All threads to be female N.P.T to specification ASME B Compression couplings shall be to BS 4368 Parts 1,2, and 3 using either single or double ferrule joints. 5.4 Valve bodies and plug may be of carbon steel to ASTM A 216 WCB or steel to ASTM - A105, stainless steel to ASTM A 351 CF 8m or to ASTM A 182 F For plug and ball parts material to be forged carbon steel to ASTM - A350LF2 ASTM - A105 or equivalent. Stainless steel to ASTM - A 182 F Stems shall be stainless steel to ASTM A 182 F 316 or equivalent. 5.7 Needle valve spindle soft tip material or body seat shall be Nylon insert or equivalent. 5.8 Where stainless steel material is used there is no necessity to include for corrosion protective measures to exposed parts. 5.9 Where carbon steel material is used corrosion protective measures shall be applied. Page 4 of 6

38 Small Bore Valves Specs. No. / MS / 010 Rev VALVE HANDLES 6.1 The selection of valve handle will be determined by the required operating mode of the valve. 6.2 For quarter turn valves, a T-bar handle is advantageous, being quick and easy to operate. Wheel handles are appropriate where a sensitive control may be necessary especially at opening/closing for example with needle valves. 6.3 For strategic located valves especially on pipe systems, consideration shall be given to the valve being lockable either in the open or closed positions. 7. TESTS AND INSPECTION The valves shall be tested and inspected according to the requirements of ANSI B and API 598. Page 5 of 6

39 Small Bore Valves Specs. No. / MS / 010 Rev TABLE OF SMALL BORE VALVES SPECIFICATION CONFOMATION TENDER NO.:... OFFER NO.:... MANUFACTURER NAME:... SPECIFICATION Type of the valve Rating - Temperature range (-5 to 100C) Design According to ANSI B The valve can pass gas in both directions Confirmation YES NO NOTES State the type Material - Body State the material - Ball State the material - Chrome Plating for forged steel ball - Plating hardness Hardness > 500 HB - Stem State the material - Seal State the material Design Safety Shall be according to item 4 Valve Handle : Acc. to item 6 Test and Inspection According to item 7 Note: Sign by ( ) for confirmed item and (X) for unconfirmed items. IMPORTANT NOTE:- 1- The vendor must submit table of confirmation completely filled and signed with the offer otherwise the offer will be cancelled. 2- Any technical deviation to this specs. must be stated clearly 3- Valve weight for 1 ball valve shouldn t exceed 6 kg and for the 1/2 the weight shouldn t exceed 3 kg Page 6 of 6

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47 Plug Valves Specs. No. / MS / 011 Rev EL TINA /NAC GAS PIPELINE PROJECT GENERAL SPECIFICATION FOR PLUG VALVES General Specification For Plug Valves Specs. No. GASCO / MS / 011 Rev. 4 Issue: Nov No. of Sheets: 27 Page 1 of 27

48 Plug Valves Specs. No. / MS / 011 Rev. 4 CONTENTS 1. Scope 2. General Service Condition 3. Materials 4. Design and Construction 5. Testing 6. Inspection 7. Data and Drawings 8. Important Notes 10. Specification Data Sheet 11. Appendices Appendix A Appendix B Appendix C Appendix D Appendix E Appendix F Requirement of stem extension assemblies. casting material specification. Non destructive testing procedures for casting produced in large quantities. Non destructive testing procedures for casting produced in small quantities. ultrasonic inspection Painting Specification for Aboveground & Underground facilities. Page 2 of 27

49 Plug Valves Specs. No. / MS / 011 Rev. 4 GENERAL SPECIFICATION FOR PLUG VALVES 1.0 SCOPE Valves to this specification will be for high pressure natural gas. 1.1 All valves shall comply with the requirements of ANSI B 31.8 American Standard Code for pressure piping supplemented by department of transportation federal safety regulations, as appropriate. 1.2 Valves shall be made in accordance with API 6D specification for steel valves, latest edition, and with the requirements of this specification. 1.3 The table of specification to be confirmed signed and attached to the technical offer. 2.0 GENERAL SERVICE CONDITION Fluid handled : Natural Gas Maximum operating temperature : +70 C Minimum operating Temperature : -20 C Ambient temperature : -5 C to + 50 C Operating pressure : Min. 25 bar Max. 70 bar Pipeline Design pressure : 77 bar 2.4 Valves will be suitable for installation above ground with the stem extension vertical or horizontal, or buried with extended vertical stem, all as indicated in the data sheet. 3.0 MATERIALS 3.1 Material for body shall be cast carbon steel or forged carbon steel according to API 6D. Steel for castings to be made by the open hearth, electric, oxygen blown process. Forgings to be made from fully killed steel. 3.2 Material for plug shall be cast carbon steel or forged carbon steel according to API 6D. 3.3 Cast valves shall further comply with appendices B, C, D, E & F. Page 3 of 27

50 Plug Valves Specs. No. / MS / 011 Rev Carbon equivalent of the material of the area of valves where welding will be carried out at installation shall be in accordance to the following equation and shall not exceed 0.42% : Ceq = %C + %Mn + %Cr+%Mo+%V + %Ni+%Cu Where welding is carried out on pressure containing parts of valves at thickness greater than 19mm, post weld stress relief shall be carried out Charpy V Notch impact testing is required on the material of the pressure containing parts for valves where the thickness exceeds 10mm Charpy specimens shall be taken in the direction of principal grain flow, notched perpendicular to the original surface of the forging. Tests shall be carried out at C. The method of testing shall be in accordance with ASTM A370. Charpy V Notch Impact Requirements for forgings and castings: Specified tensile strength specimens (full size specimens) Less than 450 N/mm2 450 N/mm2 and above Average of three full size specimens (minimum) 27J 40J Individual size (minimum) 20J 30J Where welding ends are provided for cast and forged steel valves, the carbon content shall not exceed 0.31% 4.0 DESIGN AND CONSTRUCTION 4.1 The design and construction of valves shall comply with requirements of API standard 6D latest edition, ANSI B 31.8 and this specification Valves will be provided, as indicated on the data sheet, with flanged ends to ANSI B 16.5 or welding ends in accordance with ASME B31.8. For weld ends, where the valve material yield strength is less than the minimum yield strength of the pipe to be welded to, as indicated in the data sheet, then the weld end shall be in accordance with ASME B31.8 Appendix 1, Figure 15 e) and f), 1992 Edition All welding, including repair welding, shall comply with approved welding procedures and shall be carried out by welders qualified to approved welder qualification procedures, in accordance with ASME 1X. Page 4 of 27

51 Plug Valves Specs. No. / MS / 011 Rev ALL VALVES SHALL HAVE THE FOLLOWING Drain connection and pressure gauge connections shall be provided when necessary Stem protectors and position indicator plate shall be provided when so specified The plug valves shall be regular pattern with pressure balanced inverted conical plugs. The port area shall not be less than 60% of full bore. Cylindrical plugs are not permitted Valves 2" and above shall be designed for fire safe to BS 6755 Pt2, API 6FA or API 607 as appropriate. The supplier is to indicate on the data sheet the test standard A fire safe graphite stem seal is required The valves should be designed to accommodate a device for locking the plug assembly in the open and closed position The design shall provide for the external injection of plug and stem sealants. Where stem extensions are required in the data sheet, these facilities shall be extended above ground in accordance with Appendix A of this specification Method of sealing should be clearly specified in the offer Type and method of sealing for all the valves to be advised Three hand guns with quantity (60) sealant sticks are required in case of order with no extra price All valves to be complete with valve open and close indicator plate Valves with stem extensions should be supplied as a complete assembly of one unit. The complete assembly is to be tested for operation in the manufacturers works Where a gear box is required, it shall be of the worm type, with a side hand wheel ie, handwheel shaft at 90 0 to the valve stem. The handwheel shall be permanently marked with the direction of operation. The gear housing should be water tight. All moving parts should be in greased filled and should be capable of periodic injection of grease All gear boxes shall be provided with a relief valve to prevent over-pressurisation in the event of gland leakage, unless the design of the valve is such that it is not possible to occur. Blow out plugs shall not be permitted. Page 5 of 27

52 Plug Valves Specs. No. / MS / 011 Rev The design of yoke and extension parts will be suitable for the service Plug surfaces should be treated to reduce coefficient of friction between plug surface and body seat Full details of size and position of all body tappings shall be specified on the general arrangement drawing supplied with tenders End flanges of flanged valves shall be square with the axis of the valve to 0.5 o. Flanges shall conform to ANSI B 16.5 & MSS SP The design of the valve shall provide for a method of compensating for normal wear of the seat in service Where pressure retaining parts or assemblies are held together by means of screwed components, the valve shall be designed to prevent accidental disassembly under pressure The diameter of the hand wheel or the length of the operating lever shall be such that the total force required to operate the valve throughout its full operating range shall not exceed 350N. The direction of operation (clockwise to close) of the hand wheel or lever shall be clearly marked. When the handwheel or lever itself carries this marking it shall be non-reversible on the valve stem. Means shall also be provided on the gear box, where supplied, to show the position of the valve through out its travel Materials used for bolting shall be in accordance with ASME A193 grade B7 for bolts, and ASME A 194 grade 2H for nuts Machined faces shall receive corrosion protection with a rust preventative coating or a corrosion inhibitor each of which can be readily removed on site (e.g. by wire brushing). The ends shall be sealed to prevent ingress of dirt or moisture during transit All valves shall be painted with 2 pack epoxy urethane according to specification attached. App. F. Page 6 of 27

53 Plug Valves Specs. No. / MS / 011 Rev MARKING The information required to identify the valve shall be generally as specified in the relevant standards, with the items listed below: a) Manufacturer s Name b) Valve Size c) Serial Number d) Rating e) Maximum Operating Pressure f) Test Pressure g) Design Temperature - minimum & maximum h) Valve body material i) Stem and stem seal material j) Gross weight of assembled valve (Kg) If a valve, valve actuator gear box or stem extension is paletted separately, it shall be separately marked and identified. 5.0 TESTING 5.1 The following tests shall be performed on the material of pressure containing parts and welding ends: a) Charpy impact test according to item 3.5 of this specification b) Mechanical tests as API 6D c) Chemical test as API 6D 5.2 Tests shall be carried out to confirm compliance with the mechanical properties stated in the data sheet, the fracture toughness properties and the chemical composition as required in 3.0 above. 5.3 All valves shall be subjected to a shell hydrostatic pressure test in accordance with API STD 6D requirements. 5.4 Fire safe test certificates are to be issued to confirm compliance. 5.5 Where valves are actuated, the valve and actuator are to be tested together, to prove the function of both valve and actuator. 5.6 Hydrostatic seat test shall be carried out each of the valve as required by API 6D. It shall be operated at least twice to demonstrate satisfactory mechanical operation as well as continuous tightness after operation. 5.7 Valves shall be subjected to air seat test in accordance with the requirements of API STD 6D. Page 7 of 27

54 Plug Valves Specs. No. / MS / 011 Rev Where valves incorporate stem extension assemblies, sealant extensions must also be included. These are to be tested to the relevant seat pressure with the valve closed to check the efficiency of closing valve. 5.9 Operational torque test acc. to API 6D Appendix C The valve manufacturer shall give sufficient advance notice satisfactory to the company of the time and place at which testing is to be performed Test certificates should be submitted for verification. Stating that the valve(s) comply in all respects with requirements of API 6D Pressure Testing Methods - Attachments for sealing each end of a flanged or weld end valve which subject the valve to axial compression shall not be used in any of the hydrostatic or pneumatic tests. 6.0 INSPECTION 6.1 Cast steel valve bodies shall be subject to ultrasonic examination for evidence of cracking and porosity. 6.2 All welds joining pressure containing parts shall be subject to NDT using either x- radiography or ultrasonic technique and meet the requirements of ASME V111. All welds joining all non-pressure containing parts of valves and gear boxes shall be subject to random 10% magnetic particle inspection crack detection (MPI). Lifting lugs or brackets welded to valve bodies shall be subject to 100% MPI. 7.0 DATA AND DRAWINGS 7.1 THE MANUFACTURER SHALL PROVIDE THE FOLLOWING WITH THE OFFER Outline dimensions and mechanical details for the valve Number of complete revolutions the wheel or other operating device to close or open the valve The max. permissible, torque and the rated torque required to close or open the valve at the maximum pressure differential, as stated in the data sheet Head loss curve and data for the valve The offer shall include details of tests Detailed drawing for valve parts. Page 8 of 27

55 Plug Valves Specs. No. / MS / 011 Rev IMPORTANT NOTES 8.1 Any exceptions to this specification and data sheet shall be clearly stated in the offer. 8.2 Specifications, equivalents proposed should be stated and the supporting documents and standards that prove the equivalence of each item should be submitted with the offer. 8.3 The table of specifications attached here will be completed by the manufacturer and will be attached with the offer. In case of any offer is not included these tables complete without any item missed the offer will be rejected. 8.4 The offer will include the detailed drawings upon receipt of an order. 8.5 The offer shall include the certificate in accordance with ISO 9001 and API 6D and fire safe certificate. The offer will not be accepted if any of these certificates are not included. Page 9 of 27

56 Plug Valves Specs. No. / MS / 011 Rev. 4 TABLE OF PLUG VALVES SPECIFICATIONS CONFIRMATION INQUIRY NO. :... QUOTATION NO :... MANUFACTURE NAME :... SPECIFICATION DESIGN AND CONSTRUCTION - Size (Inch) - Drawing Number - Rating Class ANSI (600/300/50) - Standard Code API 6D - Ends Connections : Butt Welding acc. to ANSI B 31.8 Flanged R.F. end acc. to ANSI B16.5/ MSS SP 44 - Sealant Injecting point type: - Method of sealing - Maximum operating temperature 70 o C - Minimum operating temperature -20 o C Pressure Balance Dimensions CONFIRMATION OF REQUIREMENTS ITEM (1) ITEM (2) ITEM (3) ITEM (4) NOTES - Port dimensions as % of full bore State the value - Regular - Acc. to API 6D Operation - Unsheltered - Stem position vertical or horizontal - Extended stem acc. to Appendix A Valve operator - Wrench + lever - Worm gear + hand wheel acc. to item With actuator - Actuated Slam Shut - Gear box acc. to item and Materials - Material of casting acc. to App. B Page 10 of 27

57 Plug Valves Specs. No. / MS / 011 Rev. 4 TABLE OF PLUG VALVES SPECIFICATIONS CONFIRMATION (Continue) CONFIRMATION OF REQUIREMENTS SPECIFICATION ITEM (1) ITEM (2) ITEM (3) ITEM (4) NOTES - Body State the material - Plug State the material - Carbon content < 0.31% for welding ends Carbon equivalent not exceeding 0.42% : - Plug surface treatment to minimise friction item Fire Safe graphite stem seal -Stem State the material State the material State the material Valve Welding Ends : - Welding ends material should be suitable for welding to pipes specs acc. to requirements - Welding end material State material - Yield strength (PSI) State the value - Wall thick. (inch) State the value Design and construction : Acc. to item 4 - Welding end shall be acc. to ASME 31.8 Appendix I Fig. 15 e and f. TESTING - Fracture toughness of welding ends acc. to item Shell hydrostatic test pressure in PSI State the value - Seat hydrostatic test pressure in PSI State the value - Pneumatic air seat test State the value - The valve, stem extension and the operator shall be tested as one unit. - Fire safe test to API 6 FA and BS Mechanical and chemical tests to item Fracture toughness test on the pressure containing parts acc. to item 3 - Shell hydrostatic test pressure acc. to API 6D - Seat hydrostatic test pressure acc. to API 6D - Pneumatic air seat test acc. to API 6D - Operational torque acc. to API 6D App. C. Page 11 of 27

58 Plug Valves Specs. No. / MS / 011 Rev. 4 TABLE OF PLUG VALVES SPECIFICATIONS CONFIRMATION (Continue) INSPECTION SPECIFICATION - Shall be in full accordance to item 6 and App. C,D, & E, of our specs. - M.P.I. for welding ends - None Destructive test acc. to App. C, D,E MARKING acc. to item 4.3. TEST AND INSPECTION CERTIFICATES - To be provided for verification Accessories required for all quantity : - 3 hand guns for sealant injection - Sealant sticks quantity (60) VALVE COATING - 2 pack urethane acc. to GASCO specs. App. F Inspection and Testing for Valves dates should be sent to GASCO before 45 days from the suggested dates. CONFIRMATION OF REQUIREMENTS ITEM (1) ITEM (2) ITEM (3) ITEM (4) NOTES Note: 1. Sign by ( ) for confirmed item and (X) for unconfirmed items. 2. Stem Length is measured from valve C.L. IMPORTANT NOTE:- 1- The vendor must submit table of confirmation completely filled and signed with the offer otherwise the offer will be cancelled. 2- Any technical deviation to this spec. must be stated clearly. Page 12 of 27

59 Plug Valves Specs. No. / MS / 011 Rev. 4 (APPENDIX `A`) REQUIREMENTS FOR STEM EXTENSION ASSEMBLIES A.1 STEM EXTENSION A.1.1 A.1.2 A.1.3 A.1.4 A.1.5 Where provision is made for mounting a stem extension assembly, the design shall be such that the complete assembly will form a rigid unit giving a positive drive under all conditions with no possibility of free movement between the valve body, stem extension or its operator. The inner drive stem extension shall be so designed as to ensure that full engagement with the valve stem is maintained in all attitudes of the valve and stem extension assembly. Where a hollow valve stem extension (ie. inner drive stem extension) is used, provision shall be made to equalise the pressure between the bore of the stem extension and the annulus. To prevent ingress of water, the necessary vent hole shall be drilled above the level of any seat in the outer tube. The outer housing shall be fitted with a vent to atmosphere incorporating a relief valve set at 0.5 bar, to prevent pressure build up. The supply of a stem extension assembly shall include gaskets for both upper and lower mating flanges. To prevent the ingress of water, these gaskets shall be suitable to resist an external pressure of 1 bar. A.2 STEM EXTENSION PIPEWORK A.2.1 A.2.2 The supply of the stem extension assembly shall include extensions to sealant connections when specified. Separate extension lines shall be provided for each sealant injection point. The pipe shall conform to API 5L Grade B, Schedule 80, sized not less than the connection size in the main valve body. Sealant lines shall be either of butt weld or socket weld construction, except where necessary for assembly purposes the sealant lines may incorporate a break away coupling, and threaded connections may be used for the sealant valves. The connection into the valve shall be threaded or socket welded as specified. Where sockets welding is required, the connection into the valve shall be by means of a purpose made fitting. The fitting shall incorporate a tapped hole as appropriate to permit a screwed plug to be used to blank off any unused tappings. Screwed connections shall not be seal welded. The supplier shall ensure that grease or sealant does not contaminate the weld end of the threaded connection. Page 13 of 27

60 Plug Valves Specs. No. / MS / 011 Rev. 4 Page 14 of 27

61 Plug Valves Specs. No. / MS / 011 Rev. 4 A.2.3 A.2.4 A.2.6 A.2.7 A.2.8 Sealant line fittings shall be 30001b as a minimum rating. Sealant line extensions shall be fitted with valves of nominal size equal to the connection size in the main valve. Two valve shall be provided, one immediately adjacent to the valve body and one adjacent to the upper flange of the stem extension. Valves shall be to a rating of 10,0001b/in 2 rating. Sealant lines assemblies shall be hydrostatically pressure tested. Testing may be carried out by means of a shop test on sub-assemblies. The test pressure shall not be less than 1.25 times the maximum pressure developed by the contractors recommended sealant gun. The sealant line shall be adequately supported from the outer extension tube, which shall not be drilled to provide such support. Where it is agreed that a stem extension is supplied separate from the valve, the sealant and bleed lines shall be trial assembled and provision shall be made for adjustment during site assembly. All items / assemblies shall be clearly and individually identified as to duty and position. Stem extension pipework shall be match marked prior to dispatch. Page 15 of 27

62 Plug Valves Specs. No. / MS / 011 Rev. 4 (APPENDIX 'B') CASTING MATERIAL SPECIFICATION B.1 The steel shall be made by open hearth, electric, oxygen blown process. The chemical composition as determined by the cast analysis of the steel used in manufacture shall normally comply with the requirements for API 6 D, Table 3.1. B.2 Each founder shall establish for his specific manufacturing procedure the limit on nitrogen allowed and the range of deoxidizers required to ensure the absence of significant porosity, type II sulphides and any susceptibility to intergranular fracture in the castings produced. B.3 The manufacturing procedure shall include, where applicable, but not be limited to the following. Steel making process, fettling, cleaning and/or pickling, initial assessment, heat treatment, methods and scope of analysis and mechanical testing, non-destructive testing (NDT), rectification fabrication, rough machining, pressure testing, final inspection including N.D.T and dimensional checks. B.4 Mechanical properties The mechanical properties shall be as specified in the table below. Mechanical tests shall be made on samples taken from each cast or heat treatment batch. All tests shall be taken from test bars in the fully heat treated condition and shall comply with the properties in the table below. If test bars are cast attached to the castings, they shall not be detached until after completion of heat treatment. When separate test bars are used, they shall be cast from the same heat of steel as the castings they represent and shall be subject to full heat treatment with those castings. TABLE : MECHANICAL PROPERTIES PROPERTIES MINIMUM VALUES 0.2% proof stress 240 N/mm 2 Elongation (5.65 A = Gauge length) Min. 24% - 25% Fracture toughness properties in accordance with 3.0 of this specification. Page 16 of 27

63 Plug Valves Specs. No. / MS / 011 Rev. 4 B.5 Stage inspection by the founder During production, the castings shall be examined for defects by the founder at appropriate stages of manufacture. Stage inspection shall include NDT as follows: a) Visual examinations b) Magnetic particle inspection (MPI) c) Ultrasonic and/or radiographic examination The methods and acceptance criteria for the non-destructive inspection of castings shall be based on BS 5998, or equivalent of ASME V111. Appendix 'C' and 'D' attached specify the extent of testing and there acceptance levels. Where the casting has machined butt - weld ends, radiography shall be carried out on those areas for a distance of 25 mm from the weld end preparation in accordance with the methods defined in BS 5998 or equivalent of ASME VIII. The quality acceptance levels for ultrasonic examination are specified in Appendix 'E' attached. B.6 RECORDS Records shall be retained for five years from the date of manufacture of castings. Such records shall include: a) Heat treatment b) Details of chemical analysis and mechanical test results c) Sketches indicating the position and extent of any major weld rectification. d) Records relating to ultrasonic and radiographic examination. e) Manufacturing & welding records / procedures. Welder qualifications in accordance with ASME Section 1X (Latest Edition) These records will also be formatted as per documentation indicated in Page 17 of 27

64 Plug Valves Specs. No. / MS / 011 Rev. 4 (APPENDIX C) NON-DESTRUCTIVE TESTING PROCEDURES FOR CASTINGS PRODUCED IN LARGE QUANTITIES C.1 GENERAL This appendix specifies the extent of testing and acceptable quality levels for castings produced in large quantities. The quality levels are those defined in BS C.2 EXTENT OF INSPECTION C.2.1 Class 400 and below (all sizes) and class 600 ( 450 mm nominal size) Individual castings shall be inspected up to the limiting defined in Table C.1 Table C.1 - Numbers of accepted consecutive castings Nominal size mm Quantity Up to and including Over 100 Up to and including 200 Over 200 Up to and including Over NOTE - The above quantities may be achieved by the summation of identical castings produced for separate orders. Following satisfactory inspection of individual castings to the numbers defined in Table C.1 inspection shall be reduced to 10% of castings from each cast. C.2.2 Class 600 (greater than 450 mm nominal size) and classes above class 600 Every casting shall be examined. Page 18 of 27

65 Plug Valves Specs. No. / MS / 011 Rev. 4 C.3 ACCEPTANCE QUALITY LEVELS C.3.1 The acceptance quality levels for the body of the castings are defined in Table C.2 C.3.2 For casting with butt weld ends, the quality level for the weld preparation and the adjacent 25 mm shall be 1. Table C.2 - Acceptance quality levels. Position in casting Class/size sequence (1) 150 1st batch Quality level Plug Others IV IV Nominated area (2) All accessible surfaces subsequent 10% samples IV IV Critical areas 300,400 1st batch III I Critical areas 600( 450mm) 600 (> 450 mm) and 600+ Subsequent 10% samples III I Critical areas All III I Critical area NOTES 1. '1st batch' is defined by the quantities in Table C.1 2. 'Critical areas' includes changes in section, fillet radii and any other areas stipulated to the foundry by GASCO. Page 19 of 27

66 Plug Valves Specs. No. / MS / 011 Rev. 4 (APPENDIX D) NON-DESTRUCTIVE TESTING PROCEDURES FOR CASTING PRODUCED IN SMALL QUANTITIES D.1 GENERAL This appendix specifies the extent of testing and acceptable quality levels for castings produced in small quantities. The quality levels are those defined in BS D.2 EXTENT OF INSPECTION AND ACCEPTANCE LEVELS D.2.1 D.2.2 The extent of inspection and acceptance quality levels for the body of the castings are specified in Table D.1 For castings with butt weld ends, the quality level for the weld preparation and the adjacent 25 mm shall be 1. Table D.1 - Extent of inspection and acceptance levels. Class < 150 1st off Position in casting sequence Quality level Plug Others IV IV Nominated area* All accessible surfaces All subsequent castings IV IV Critical areas > 150 1st off III I - All subsequent castings III II Critical areas * 'Critical areas' includes changes in section, fillet radii and any other areas stipulated to the foundry by GASCO Page 20 of 27

67 Plug Valves Specs. No. / MS / 011 Rev. 4 (APPENDIX E) ULTRASONIC INSPECTION E.1 Ultrasonic inspection shall be in accordance with BS 6208 or equivalent of ASME VIII. E.2 Table E.1 lists the quality levels from BS 6208 which shall be considered equivalent to the ASTM radiographic acceptance levels specified in BS 5998 or equivalent of ASME VIII. Table E.1 - Quality levels for ultrasonic inspection Discontinuity Type ASTM severity level BS 6208 quality level. A 2 3 B 2 3 CA CB CC 2 4 CD Page 21 of 27

68 Plug Valves Specs. No. / MS / 011 Rev. 4 Casting inspection and acceptance levels for - Appendix C,D, E Reference to BS 5998, BS 6208 and ASTM E446 Appendix C Table C.2 should be read together with the following tables from B.S 5998: Table 1 - Quality Levels and inspection requirements. Quality Level Visual Inspection Requirements Magnetic Particle (MPI) Radiographic I 100% of pressure 100% of pressure All containing parts containing parts pressure II containing Nominated areas Nominated areas III parts IV Table 2 - Acceptance standards for castings up to 51 mm thickness (For reference radiographs see ASTM E446-78) Severity Level Discontinuity Type Gas porosity Sand and slag inclusions Shrinkage Type CA Type CB Type CC Type CD Category A B C C C C Other than buttweld ends Casting Quality Level Butt-Weld ends Casting Quality Level III 1 and II I,II,III } } } } All Level 2 } } Page 22 of 27

69 Plug Valves Specs. No. / MS / 011 Rev. 4 Table 3 - Acceptance standards for castings between 51 mm and 114 mm thickness (For reference radiographs see ASTM E186-75) Severity Level Discontinuity Type Gas porosity Sand and slag inclusions Shrinkage Type 1 Type 2 Type 3 Category A B C C C Other than buttweld ends Casting Quality Level Butt-Weld ends Casting Quality Level III 1 and II I,II,III } } } All Level 2 } } Table 4 - Acceptance standards for castings between 114 mm and 305 mm thickness (For reference radiographs see ASTM E280-75) Severity Level Discontinuity Type Gas porosity Sand and slag inclusions Shrinkage Type 1 Type 2 Type 3 Category A B C C C Other than buttweld ends Casting Quality Level Butt-Weld ends Casting Quality Level III 1 and II I,II,III } } } } All Level 2 } This also is the key to the requirements in Appendix D Reference to Table C2 and Table 1 determines the required levels and types of NDT. Reference to Tables 2,3 & 4 determine the approval levels to be used in consultation with the radiographic charts available from ASTM. Page 23 of 27

70 Plug Valves Specs. No. / MS / 011 Rev. 4 Example - Class mm nominal size valve body up to 51 mm thickness. From Table C2 the quality level is found under "Others" and is I. From Table 1, visual, 100% MPI and 100% radiography are required. From Table 2, the acceptance standards shown in the ASTM charts can then be established e.g. Gas porosity would be at severity level 2 for body and butt-weld area. Appendix E - Ultrasonics In order to determine quality levels relative to radiography, Table E1 relates the discontinuity types to those defined in Table 2. From Table 2 the severity level can be determined. Table E1 then allows the determination of the BS 6028 Quality level. Information from BS 6028 is required as follows: Table 5. Planar discontinuities; quality levels Limits of indicated dimensions of discontinuity in a frame, 317 mm* 317 mm (100,000 mm 2 ) 1 (See note 1) Quality level Maximum indicated through-wall length of a single defect (mm) Maximum indicated area of single discontinuity (mm 2 ) (See note 2) Maximum total indicated area of discontinuities (mm 2 ) Note 1 To be advised if required Note 2 To be advised if require Table 6 - Non Planar discontinuities: quality levels Zone Limits of indicated dimensions of discontinuity in a frame 317mm* 317 mm (100,000 mm 2 ) See Note 1 Outer Max. indicated discontinuity size(% of zone thickness) Max. individual indicated discontinuity area (mm 2 ) Max. indicated total area of discontinuities (mm 2 ) Mid Max. indicated discontinuity size(%of zone thickness) Max. indicated total area of discontinuities (mm 2 ) Notes; To be advised if required Quality Level Page 24 of 27

71 Plug Valves Specs. No. / MS / 011 Rev. 4 With the quality level determined in table E2, the acceptance standards for defects disclosed by ultrasonic examination can then be established from table 5 & 6. Example : Same casting as before Same gas porosity as before i.e. severity level 2 From Table E.2 a Type A discontinuity of (ASTM) severity level 2 requires as BS 6208 quality level of 2. With this quality level, the acceptance limits can be established in tables 5 & 6 For reference :- British Standards BS Specification for quality requirements of steel valve castings BS Method of ultrasonic testing of ferritic steel castings including quality level. Page 25 of 27

72 Plug Valves Specs. No. / MS / 011 Rev. 4 (APPENDIX F) SPEC. 1 Painting PAINTING SPECIFICATION FOR ABOVE GROUND FACILITIES * For pipes, valves, bends and other fittings. Paint cycle shall be as follows: Surface preparation: sa st Layer : Zinc Epoxy, 1 coat DFT 75 µm. 2 nd Layer : High Built (HB) Epoxy 200 µm. 3 rd Layer : Polyurethane (PU) 50 µm. Total DFT Final Color : 325 µm. : RAL 7035 Light Gray Page 26 of 27

73 Plug Valves Specs. No. / MS / 011 Rev. 4 SPEC. 2 Painting PAINTING SPECIFICATION FOR UNDER GROUND PAINTING OPERATIONS CHART FOR 2-PACK EPOXY COATINGS Period before OPERATIONS Handling or next coating operation No. Description Min. Max. 1 Blast clean. 4h COMMENTS for Sa 2 1/2 (1S ) Profile micro 2 Clean all surfaces 2 24 To remove contamination Spray or Brush apply layer of coating material Moisture tolerant epoxy (Dry or moist surfaces) Apply further layers to give 2.5 mm. minimum thickness For moist or dry surfaces Surface must only be damp (i.e. no water droplets forming) Typical film thickness (wet or dry) 250 microns Use 2 colours of material. Altemate colour for each layer of coating and brush at right angles to previous layer. Final Color : RAL 7035 Light Gray Page 27 of 27

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79 ENGINEERING DEPARTMENT ES/01/REV2 ELECTERICAL TECHINCAL SPECIFICATIONS ELECTRICAL TECHNICAL SPECIFATIONS Issue Date: 1 st JAN 2018 No. of Sheets 6 1

80 ENGINEERING DEPARTMENT ES/01/REV2 ELECTERICAL TECHINCAL SPECIFICATIONS REFERENCE CODES AND STANDARD All supplied electrical materials should comply with the following codes and standards: - International Electrotechnical Commission (IEC) IEC IEC IEC IEC IEC Standard Voltages. Electrical apparatus for explosive gas atmospheres. Calculation of the Continuous Current Rating of Cables. Electrical Installation of buildings. Degrees of protection provided by enclosures. - American Petroleum Institute (API) API RP 540 API RP 14F API RP 500 Electrical installations in petroleum processing plants. Recommended practice for design and installations of electrical systems for offshore production platforms. Recommended practice for classification of locations for electrical installations at petroleum facilities. 2

81 ENGINEERING DEPARTMENT ES/01/REV2 ELECTERICAL TECHINCAL SPECIFICATIONS First: Electrical distribution panel: The electrical distribution panel should comply with the following requirements: Outdoor weatherproof distribution panel 380/220 V, 50 HZ, IP 55, 36 KA short circuit. Distribution panel shall be equipped with the following: - One incoming moulded case circuit breaker, 100 A, 36 KA, 3 pole feed : One contactor 125 A, 380 volt controlled by over / under voltage relay and phase Sequence relay. The main incoming Circuit breaker feed the following Branch Circuit breakers 1- One MCCB 50 A,25 KA, 380 V, 3PH, 3 POLE. One contactor 380 V, 63 AMP at AC1 auxiliary Contacts and controlled by 2 positions: Automatic (Photo cell) and Manual Positions - (6) branch circuits with miniature circuit breakers each rated 20 A, 15 KA, 380 V 3 PH, 3 Pole 2 - ONE MCCB 63A, 380 V, 3PH, 3 POLE, 15 KA 3- One MCCB 63A, 15 KA, 380 V, 3PH 3 POLE feeding the following breakers: * (1) MCB 63 A, 10 KA, 220 V, 1PH, 1 POLE *(2) MCB 32 A, 10 KA, 380 V, 3PH, 3 POLE *(5) Indicating lamps * (2) Push Buttons * (3) Ammeters * (1) Voltmeter * Selector switch (manual/off / automatic) * (1) Photocell for Control of Lighting Contactor - Drilled gland plate complete with suitable cable glands threaded corrosion resistant, brass material provided with double sealing rings, armor clamping a polychloropylene (PCP) for shroud and all accessories such as lock nuts, gaskets, earth tags etc suitable for the following cables : * (1) explosion proof cable gland for Non Armored earthing cable stranded copper conductors 1x 95 mm2. * Explosion proof cable glands suitable for Stranded copper conductors 0.6/1KV XLPE insulated, inner PVC sheath, galvanized steel wire armor as follows: * (1) explosion proof cable gland for 4x35 mm2 cable. * (5) Explosion proof cable gland for 4x 10 mm2 cables. * One Explosion proof plug for 4x10 mm2 cables The panel should satisfy the following requirements: Corrosion resistance steel enclosure with sloped shed. * Degree of protection IP 55 * Reversal door with key locking handle. * The panel should be suitable for mounting on a concrete basement. 3

82 ENGINEERING DEPARTMENT ES/01/REV2 ELECTERICAL TECHINCAL SPECIFICATIONS * Standard bus bar arrangements withstand short circuit current for incoming and outgoing MCCB and MCBs. * Separate bus bar for neutral connection. * Brass earth terminal connections. * The panel board is supplied complete with all accessories such as plugs, brass Glands, lugs, terminals, wiring, photo cell All MCCB and MCBs are with over current and short circuit protection. The shop drawings and wiring diagram for the distribution panel shall be submitted All necessary and required testing for the panel shall be done at the panel factory. Second: Lighting fixtures A) High pressure sodium explosion proof Fixture type: EEX de IIB T3, IP 65, 230 V, 400 watt Flood lighting fixture,complete with:- * 400 watt color corrected high pressure sodium lamp complete with: * Relevant hot galvanized support. * Capacitors to improve Power factor to 0.9 min * Reflector & glass protection. * Conventional ballast and igniter. * The fixture shall be complete with a threaded entry & terminal strip to receive a lighting cable of 3x2.5 mm2 and complete with one explosion proof cable gland & one plug. * EEXde, IIB T3, IP 55 pole junction box compete with the following: * MCB 10 amp * 2 threaded entries, each threaded entry is suitable for a lighting Armored cable 4x10mm2 (from bottom) * One threaded entry suitable for armored lighting cable of 3x2.5 mm2 (From top) * Nine terminal strip (3L+3N+3G jumpered 3 by 3) * 2 Explosion proof cable glands EEXde, IIB T3, IP 55 compatible With junction box complete with all accessories suitable for two armored lighting Cables 4x10mm2 * One Explosion proof cable gland EEXde, IIB T3, IP 55 Compatible with Junction box complete with all accessories suitable for 3x2.5mm2 Armored Lighting cable * All required installation accessories such as bolts, nuts, washers etc B) LED lighting fixtures : EEx db IIB T4, IP 66, 210 watt lighting fixture Fixture operating time should not be less than 50,000 hours, fixture guarantee time should be minimum 5 years. The fixture shall be complete with a threaded entry & terminal strip to receive a lighting cable of 3x2.5 mm2 and complete with all accessories and cable glands. * EEXde, IIB T3, IP 55 pole junction box compete with the following: * MCB 10 amp * 2 threaded entries, each threaded entry is suitable for a lighting Armored cable 4x10mm2 (from bottom) 4

83 ENGINEERING DEPARTMENT ES/01/REV2 ELECTERICAL TECHINCAL SPECIFICATIONS * One threaded entry suitable for armored lighting cable of 3x2.5 mm2 (From top) * Nine terminal strip (3L+3N+3G jumpered 3 by 3) * 2 Explosion proof cable glands EEXde, IIB T3, IP 55 compatible With junction box complete with all accessories suitable for two armored lighting Cables 4x10mm2 * One Explosion proof cable gland EEXde, IIB T3, IP 55 Compatible with Junction box complete with all accessories suitable for 3x2.5mm2 Armored Lighting cable * All required installation accessories such as bolts, nuts, washers etc Third: Lighting poles Hot dip galvanized steel flood lighting pole 8 meter height (5 mm thickness) & shall withstand wind speed of 160 km / hr suitable for item 2 (Lighting Fixture) with all required related accessories. Connection from pole junction box to distribution junction box shall be through explosion proof cable gland and Poles bushing. Fourth L.V. CABLES Stranded copper conductors 0.6/1KV XLPE insulated, inner PVC sheath, galvanized steel wire armor and black colored flame retardant PVC outer sheath. Cables shall be 4 core (R,S,T,N ) for 3 ph. feeders with red, yellow, blue & GREEN cores for R, S, T and N respectively. Fifth: Earthing system specifications * The earthing system shall consist of ground rods driven in earth and embedded Ground cable connected to the ground rods. Individual pieces of equipment shall be connected with jumpers to the ground loop. * Ground rods shall be copper clad steel * The main ground grid cable size is 95 mm 2. The earthing system consists of the following items: 1- Copper clad steel earth rod having a (3/4 " shank diameter of 17.2 mm) 20 mm and 3 meter long composed of two sections each 1.5 meter complete with the following:- *Coupling dowel type. * Self-spiked at the end * Earth rod to cable clamp complete with two lugs for 95 mm2 earthing conductors, Bolts, nuts, washers, etc * driving stud * Earthing Concrete Inspection Pit 2- Earthing copper bar, with 80 x12x 390 mm dimension, 8 holes, complete with all necessary accessories (connection lugs, stainless steel bolts, nuts, flat washers 5

84 ENGINEERING DEPARTMENT ES/01/REV2 ELECTERICAL TECHINCAL SPECIFICATIONS and lock washers,.. etc) suitable for connection of two cables each 95 mm2 to the end holes and another 6 for cables 16 mm2. 3- Equipment tap suitable for earthing cable 95 mm2 complete with all necessary accessories and fittings (connection lugs, stainless steel bolts, nuts, flat washers and lock washers,..etc). 4- Equipment tap suitable for earthing cable 16 mm2 complete with all necessary accessories and fittings (connection lugs, stainless steel bolts, nuts, flat washers and lock washers,..etc). 5- Tinned copper compression cable connector (C-Clamp) For 95/95 mm2. 6- Tinned copper compression cable connector (C-Clamp) For 95/16 mm2. 7- Ground Enhancement Material (Bentonite ) 8-450/750 V, Non Armored earthing cable stranded copper conductors, Single core Yellow/green PVC insulated cables with size 1*95mm /750 V, Non Armored earthing cable stranded copper conductors, Single core, yellow/green PVC insulated cables with size 1*16mm2 10- Cable Lugs for cable 1*95 mm2 11- Cable Lugs for cable 1*16 mm2 6

85 Page 1 of 4 Egyptian Natural Gas Co. G A S C O Gen. Dept. of Engineering Affairs Material Requisition Project name: RAVEN / W.D.G.C Gas Pipeline Project Material Specs. no. Project no. ES/ Electrical materials Specs. rev. Requisition no. ES/01/REV2 Material Requisition Status Rev. no. Date Revisions Originator Approval 0 5/02/2018 Issue for Tender

86 Page 2 of 4 G A S C O Continuation Sheet Supply of the following materials complete according to the attached specifications: REQN. no. PRJ. no. Rev. Date /2/2018 Item Description Unit QTY. Unit Price Total Price 1 2 Supply, Inspect and Test an Outdoor weatherproof distribution panel 380/220 V, 50 HZ, IP 55, 36 KA short circuit High pressure sodium explosion proof Fixture type : EEX de IIB T3, IP 65, 230 V, 400 wa flood lighng fixture EACH 3 EACH LED Ex IIB T3 IP wa lighting fixture. EACH 6 3 Hot dip galvanized steel flood lighng pole 8 meter height (5 mm thickness) EACH 18 4 Low Voltage Cables Stranded copper conductors 0.6/1KV XLPE insulated, inner PVC sheath, galvanized steel wire armor and black colored flame retardant PVC outer sheath 4.1 4*35 mm2 METER *10 mm2 METER x2.5 mm2 Cables shall be 3 core (L,N,G) with red, green, & yellow green cores for L,N,G respectively METER 350

87 Page 3 of 4 5 Earthing concrete inspection pit including all required Components and accessories Complete with -Copper clad steel earth rod having a (3/4 " shank diameter of 17.2 mm) 20 mm and 3 meter long composed of two sections each 1.5 meter complete with the following: a) Coupling dowel type. b) ) Earth rod to cable clamp (suitable to 95 mm2 cable lug entries and 95mm2 cable lug exit) complete with two lugs for 95 mm2 earthing conductors, bolts, nuts, washer, etc c )Driving stud d) Earthing Concrete Inspection Pit EACH Copper clad steel earth rod having a 3/4 Shank diameter of (17.2 mm) 20 mm and 1.5 meter long EACH 100 Coupling dowel type EACH Earthing copper bar, with 80 x12x 390 mm dimension, 8 holes, complete with all necessary accessories (connection lugs, stainless steel bolts, nuts, flat washers and lock washers,.. etc) suitable for connection of two cables each 95 mm2 to the end holes and another 6 for cables 16 mm2. Equipment tap suitable for earthing cable 95 mm2 complete with all necessary accessories and fittings (connection lugs, stainless steel bolts, nuts, flat washers and lock washers,..etc) Equipment tap suitable for earthing cable 16 mm2 complete with all necessary accessories and fittings (connection lugs, stainless steel bolts, nuts, flat washers and lock washers,..etc) Flexible copper bonding jumper. nickel plated copper flexible bonding jumper, 400 mm, 16 mm2 cross section area complete with end lugs, Stainless Steel bolts, nuts, flat washers, spring washers and all required fixation accessories for steel doors bonding. EACH 20 EACH 50 EACH 320 EACH Tinned copper compression cable connector (C-Clamp) For 95/16 mm2 EACH 240 Bentonite Powder Form TON 5

88 Page 4 of /750 V, Non Armored earthing cable stranded copper conductors, Single core, yellow/green PVC insulated cables with size 1*95mm2 450/750 V, Non Armored earthing cable stranded copper conductors, Single core, yellow/green PVC insulated cables with size 1*16mm2 METER 5000 METER 6500

89 Egyptian Natural Gas Co. G A S C O Gen. Dept. of Engineering Affairs MATERIAL REQUISITION Project Name: RAVEN /W.D.G.C GAS PIPELINE MATERIAL Specs No. Project No. GASCO / MS / Cathodic Protection MATERIAL REQUISITION STATUS Specs. Rev. REV. 2 Requisition No. Rev. No. Date Revisions ORIGINATOR REVIEW APPROVAL 0 5/2/2018 Issue for Tender Page 1 of 15

90 CONTINUATION SHEET G A S C O REQN. No. PRJ. No.: REV.: DATE: /2/2018 ITEM DESCRIPTION UNIT QTY. UNIT PRICE TOTAL PRICE 1 Transformer Rectifier, Outdoor, Oil Cooled. 220V A.C, 1 Phase, 50 Hz, O/P : 48 Volt DC, 30 Amp DC as per specs. No. (1) NO "X60" Fe-Si-Cr Anode, each anode shall be supplied with Cable XLPE/PVC insulated, 1x16 mm2, size 25 m length as per specs. No. (2) NO Single zinc earthing electrode as per specs No. (3) NO High Potential Magnesium Anode as per specs. No. (4) Weld Cartridges for Steel Pipeline & Cable (15gm) as per specs. No. (5) Carbon Mold C/W Hand Leaned Suitable for 1x16mm 2 of horizontal steel pipe as per specs. No. (5) NO. 30 NO. 200 NO. 5 Page 2 of 15

91 7 Carbon Mold C/W Hand Leaned Suitable for 1x16mm 2 of vertical steel pipe as per specs. No. (5) NO. 2 8 Handy Cap Royston C/W Spray Primer as per Specs No. (5) NO Flint Gun with Complete Spares as per specs. No. (5) NO solid state polarization cell replacement (PCR) as per specs. No. (6) NO Pin Brazing (Easybond MKII PIN BRAZING SYSTEM) as per specs. No. (7) NO MCM Portable Cu/Cu So 4 reference electrode model (RE-5) NO Fluke 179 True RMS Digital Multimeter c/w basic Accessories NO. 3 Page 3 of 15

92 Cathodic Protection Material and SPECIFICATIONS General Department of Engineering Affairs CATHODIC PROTECTION MATERIAL SPECIFICATIONS RAVEN /W.D.G.C Gas Pipeline Project Page 4 of 15

93 Cathodic Protection Material Technical Specification General Department of Engineering Affairs Specification no. 1 TRANSFORMER - RECTIFIER EQUIPMENT * Manufacture Data Sheet Must Be Submit. 1- Type : Outdoor oil filled base mounting. 2- Supply : Single phase input (220 V - 50 Hz) 3- Output : D.C. VOLTS: 48 V D.C. AMPS: 30 A 4- Control : Manual Control system On Load variation of output voltage by stepless auto-transformer connected in main transformer primary. Control range is from 0% to 100%. 5- Climatic Conditions: Outdoor units designed to operate in shade ambient temperatures of up to 50 C, with a degree of protection against dust and water to IP Transformers : All Transformers are manufactures and tested in accordance with BS 171, IEC Rectifiers : Silicon diode, full wave rectification circuit, reduce ripple to 5%. 8- Protection : Complete protection for both input and rectifier sides. Suitable for material and conditions supplied. 9- Meters : Voltmeters, Ammeter rating indication for each equipment. A.C. Input Voltmeter D.C. Output Voltmeter D.C. Output Ammeter RAVEN /W.D.G.C Gas Pipeline Project Page 5 of 15

94 Cathodic Protection Material Technical Specification General Department of Engineering Affairs 10- Enclosures : Oilfield Equipment: Oil tank and integral control, instrument enclosure are fabricated from 3.00 mm. Thick steel and supplied complete with the following: - Oil drain valve with protective kick-plate. - Oil filler/thermometer pocket. - First filling of oil to BS Silica-gel breather. - Rolled steel channel base for plinth mounting. - Lifting lugs. - Sunshades. - External earthing terminal. - Rating plate (stainless steel). 11- Finish : External surface of equipment treated as follows:- 1- Surface cleaning by shot blast to S.A.2.5 (or BS 4232). 2- Zinc flame spray 100 microns D.F.T. prime. 3- TOPCOAT stove enamels gray total Paint D.F.T. 100 microns. : Internal surface of oil tank is thoroughly, degreased and painted. 12- A copy from test certificate must be enclosed with complete set from wiring diagram, and trouble-shooting manual. RAVEN /W.D.G.C Gas Pipeline Project Page 6 of 15

95 Cathodic Protection Material Technical Specification General Department of Engineering Affairs Specification no. 2 IRON - SILICON - CHROMIUM ANODES * Manufacture Data Sheet Must Be Submit. 1- PURPOSE: This specification covers the requirements for the supply Iron - Silicon anodes to be used for ground beds of the impressed current system. 2- CHEMICAL COMPOSITION: 2.1 Reference Codes: ASTM A Grade 3 (Rod Anode) The Anodes have these compositions: - Silicon 14.5 % - Chromium 4.5 % - Manganese 0.75 % - Carbon 0.95 % - Iron: Remainder 3- TECHNICAL DATA: - Length : 1525 mm (60") - Diameter : 50 mm (2") - Weight : 22.7 KG. - Consumption rate : 0.25 KG/ A. year 4- GENERAL DATA : 4.1 The single ended anodes shall be supplied complete with a single core copper XLPE/PVC insulated 1000 V. grade. RAVEN /W.D.G.C Gas Pipeline Project Page 7 of 15

96 Cathodic Protection Material Technical Specification General Department of Engineering Affairs - Size : 16 mm 2 - Length : 30 m - Resistance : 1.14 Ohm/km (20c) 4.2 The connection between cable and anodes shall be cast into a cared chamber and joint shall be encased in Epoxy compound with heatshrink Cap. 5- CERTIFICATION: 5.1 Physical, mechanical and electric properties certificate. 5.2 Chemical composition analysis certificate 5.3 Copy from the Q.C. data sheets. 5.4 Technical data sheets covering cathodic protection materials manufactures by your company. 6- PACKING FOR SHIPMENT: To protect the anode and cable assembly during transportation, extreme care shall be taken and the following requirements shall be kept. : - Anodes shall be packed in shock absorption material e.g. polyurethane FOAM. - The anode cable shall be wound on a DISPOSAL spool to prevent damage during shipment. - Total anodes assembly number per crate (wooden case) shall not exceed 10 anodes. RAVEN /W.D.G.C Gas Pipeline Project Page 8 of 15

97 Cathodic Protection Material Technical Specification General Department of Engineering Affairs Specification no. 3 SINGLE ZINC EARTHING ELECTRODE * Manufacture Data Sheet Must Be Submit. 1- Purpose: This specification covers the requirements for the supply single zinc earthing electrode to be used to reduce the danger of electric shocks arcing and damages. 2- Chemical composition AL 0.1 % % Fe % max. Cd % % Pd % max. Zn Remainder 3- Technical Data - DIMENTION : 60" x 1.4" x 1.4" (without backfill) - PACKAGED WEIGHT : 95 lbs. (Minimum) 4- Backfill Composition Powdered Gypsum 75% Granular Bentonite 20% Sodium Sulphate 5% 5- The single ended anodes shall be supplied complete with a single core copper XLPE/PVC insulated 1000 V. grade. RAVEN /W.D.G.C Gas Pipeline Project Page 9 of 15

98 Cathodic Protection Material Technical Specification General Department of Engineering Affairs - Size = 16 mm 2 - Length = 10 m - Resistance = 1.14 Ohm/km (20c) 6- CERTIFICATION: 6.1 Physical, mechanical and electric properties certificate. 6.2 Chemical composition analysis certificate 6.3 Copy from the Q.C. data sheets. 6.4 Technical data sheets covering cathodic protection materials manufactures by your company. 7- PACKING FOR SHIPMENT: To protect the anode and cable assembly during transportation, extreme care shall be taken and the following requirements shall be kept. : - The anode cable shall be wound on a DISPOSAL spool to prevent damage during shipment. - Total anodes assembly number per crate (wooden case) shall not exceed 10 anodes. RAVEN /W.D.G.C Gas Pipeline Project Page 10 of 15

99 Cathodic Protection Material Technical Specification General Department of Engineering Affairs Specification no. 4 HIGH POTENTIAL MAGNESIUM ANODES * Manufacture Data Sheet Must Be Submit. 1- CHEMICAL COMPOSITION AL 0.01 % max. Mn 0.5 % % Si 0.05 % max. Ni % max. Cu 0.02 % max. Fe 0.03 % max. others 0.3 % max. Mg Remainder 3- TECHNICAL DATA - DIMENTION : 25.5 " x 3" x 3" (Minimum) -without backfill - NET WEIGHT : 7.7 KG. (Minimum) - PACKAGED WEIGHT : 15 KG. (Minimum) 4- BACKFILL COMPOSITION Powdered Gypsum 75% Granular Bentonite 20% Sodium Sulphate 5% 5- The single ended anodes shall be supplied complete with a single core copper XLPE/ (red color) PVC insulated 1000 V. grade. RAVEN /W.D.G.C Gas Pipeline Project Page 11 of 15

100 Cathodic Protection Material Technical Specification General Department of Engineering Affairs - Size = 16 mm 2 - Length = 10m - Resistance = 1.14 Ohm/km (20c) 6- CERTIFICATION: 5.1 Physical, mechanical and electric properties certificate. 5.2 Chemical composition analysis certificate 5.3 Copy from the Q.C. data sheets. 5.4 Technical data sheets covering cathodic protection materials manufactures by your company. 7- PACKING FOR SHIPMENT: To protect the anode and cable assembly during transportation, extreme care shall be taken and the following requirements shall be kept. : - The anode cable shall be wound on a DISPOSAL spool to prevent damage during shipment. - Total anodes assembly number per crate (wooden case) shall not exceed 20 anodes. RAVEN /W.D.G.C Gas Pipeline Project Page 12 of 15

101 Cathodic Protection Material Technical Specification General Department of Engineering Affairs Specification no. 5 WELDING AND COATING EQUIPMENT * Manufacture Data Sheet Must Be Submit. 1- Weld cartridges for steel pipelines and cable (15 gm). 2- Carbon mold C/W hand leaned suitable for Horizontal steel pipelines and cable 1*16 mm Carbon mold C/W hand leaned suitable for Vertical steel pipelines and cable 1*16 mm Flint gun with 10 flints spares for each. 5- Reyoston Handy cap. 6-1 no. of Spray primer (Raybond 747)/ 20 handy cap. RAVEN /W.D.G.C Gas Pipeline Project Page 13 of 15

102 Cathodic Protection Material Technical Specification General Department of Engineering Affairs Specification no. 6 Solid-State Polarization Cell Replacement (PCR) * Manufacture Data Sheet Must Be Submit. AC Fault Current Ratings (30 cycle): 5,000 Amp Steady-State Current Ratings: 45 Amp DC Blocking Voltage Rating: -3.0 volts to +1.0 volt Lightning Surge Current Rating: (Peak Amperes) 100,000 IP: 65 Ambient Temperature: -45 o C to +65 o C RAVEN /W.D.G.C Gas Pipeline Project Page 14 of 15

103 Cathodic Protection Material Technical Specification General Department of Engineering Affairs Specification no. 7 Pin Brazing 1- Complete Easybond MKII unit (including all the following components): 1-1- Power Unit for Easybond MKII complete with battery pack 1-2- Easybond Gun (Standard gun) Pin holder for 8mm direct braze pins Ferrule holder for 8mm direct braze pins Toolkit Battery charger ELITE 110/230v supply Earth device Attaché case Manuals and training video on CD 2- The following Accessories For Easybond MKII: 2-1- Battery charger 12V supply - In Car Charger Extension Cable 2.5m length. 3- The following Consumables For Easybond MKII: 3-1- (300) no. of 8mm Direct Brazing Pin (200) no. of M8 Threaded Brazing Pin (80) no. of M12 Threaded Brazing Pin (200) no. of Ferrule 8mm for direct pins (100) no. of Ferrule 12mm for threaded pins (200) no. of Cable lug 16 mm² cable (100) no. of Cable lug 50 mm² cable (100) no. of Stinger #12 AWG kit. RAVEN /W.D.G.C Gas Pipeline Project Page 15 of 15

104 1. List of Goods and Delivery Schedule (The stated below delivery period shall be counted from Fax of Award date up till receiving the materials at port of destination on CIF basis, bidders offering delivery period after the latest delivery date shall be treated as Non-Responsive and the related bid will be rejected). Line Item N Description of Goods Quantity Physical unit Final (Project Site) Destination as specified in BDS Earliest Delivery Date Delivery (as per Incoterms) Date Latest Delivery Date LOT 5: Stainless Steel Fittings, Pressure Transmitters, Gauges & SCADA Equipment ICB No: GASCO/ICB/007 (According to GASCO Attached Technical Specifications) Bidder s offered Delivery date [to be provided by the bidder] 1 (RTUs) GASCO grid managed through field proven existing RTUs which include Ethernet-based RTUs of the following brands (Modicon M340, stardom FCN, SCADA pack) therefore bidders shall propose RTUs based on the above mentioned short list to maximize cost of ownership and gas grid management. 9 Each

105 1. List of Goods and Delivery Schedule (The stated below delivery period shall be counted from Fax of Award date up till receiving the materials at port of destination on CIF basis, bidders offering delivery period after the latest delivery date shall be treated as Non-Responsive and the related bid will be rejected). Line Item N Description of Goods Quantity Physical unit Final (Project Site) Destination as specified in BDS Earliest Delivery Date Delivery (as per Incoterms) Date Latest Delivery Date Bidder s offered Delivery date [to be provided by the bidder] 2 Digi 3G router WR SMART Transmitter Power Supply Analog Safety Barriers: Model No: KFD2-STC4-Ex1 OR Alternate Model No. MTL Each (*) inside RTU cabinet Each (*) inside RTU cabinet 4 MOXA Modbus gateway Each 5 Configuration laptop 2 Each 6 RTUs Programming and configuration software utility and its built-in simulation software package (RTU emulator). (2) Licenses Each 7 Fluke 715 Volt/mA Calibrator 2 Each

106 2. List of Related Services and Completion Schedule Service Description of Service Quantity 1 Physical Unit 1 Project services shall be based on turnkey EPC for whole project scope as indicated in commodities and services indicated in the doc. Supply of RTUs units that include safety barriers and digi WR21 in each RTU cabinet. Full Engineering services engineering will include as minimum (FDS, detailed engineering, configuration of RTUs with all process I/Os, interlock logic, testing procedures, time schedule, execution plan,..etc. Factory acceptance testing service (FAT attended by (No. 3 Gasco persons) at the original manufacturer certified premises (factory). SAT, provisional acceptance, final acceptance) Full procurement services Full construction (installation, pre- commissioning, commissioning, site acceptance, startup, provisional acceptance) Full training services for RTUs at Manufacture certified training facility (for : (4) GASCO persons) Engineering Drawings, workshop drawings, installation drawings, as-built drawings and full project Documentation Project Guarantee (12 month from PAC) for all project's components Project management and execution Place where Services shall be performed lot lot As per tender Final Completion Date(s) of Services As per delivery schedule

107 Compliance Form GASCO Item Spec Section NO. Compliance to GASCO Spec. List of Goods and Delivery Schedule 1 List of Related Services and Completion Schedule 2 Technical Specifications for LOT-5 ( SCADA) 3 Scope of Work and Supply 3.1 Services and commodities 3.2 Preliminary BOM Services that includes at least but not limited to Goods and Related Services in details 3.3 RTU specifications Digi 3G router WR SMART Transmitter Power Supply Analog Safety Barriers MOXA Modbus gateway Configuration laptop Engineering solution Drawings 4 Inspections and Tests 5 FC NC Notes FC: Fully comply NC: Not comply

108 3. Technical Specifications for LOT-5 ( SCADA) Summary of Technical Specifications. The Goods and Related Services shall comply with following Technical Specifications and Standards: Item No Name of Goods or Related Service Technical Specifications and Standards 1 1- RTUs: GASCO grid managed through field proven existing RTUs which include Ethernet-based RTUs of the following brands (Modicon M340, stardom FCN, SCADA pack) therefore bidders shall propose RTUs based on the above mentioned short list to maximize cost of ownership and gas grid management. 2- Digi 3G routerwr21 3- SMART Transmitter Power Supply Analog Safety Barriers 4- Moxa Modbus gateway Configuration laptop 6- Engineering solution 7- EPC engineering services 8-Fluke 715 Volt/mA Calibrator Below technical specification and engineering design

109 3.1 Scope of Work and Supply The following project will be executed under the conditions of World Bank. Bidders shall be responsible for EPC turnkey project activities as of (site survey, complete design, and fabrication, supply, installation, testing, commissioning, start-up, and guarantee, o f the connection of nine (9) Valve Rooms Sectionalizing valves along Raven pipeline). Bidder shall be responsible for all spare parts required during the mentioned site works (commissioning spare parts). N.P: The supplied RTUs shall be as per GASCO grid managed through field proven existing RTUs which include Ethernet-based RTUs of the following brands (Modicon M340, stardom FCN, SCADA pack) therefore bidders shall propose RTUs based on the above mentioned short list to maximize cost of ownership and gas grid management. 3.2 Services and commodities for The Following: No. (9) RTUs Per valves rooms for 30" Raven Gas Pipeline to include ( 9 RTUs) pre-programmed RTUs with DNP3 and Modbus TCP protocols No. (9) 3G Digi valve rooms for above pipelines (model: DIGI transport WR21) No. (36) SMART Transmitter Power Supply Analog Safety Barriers installed inside and wired inside the RTU cabinet (4 Per RTU ) to power the pressure transmitters instruments RTUs Programming and configuration software utility and its built-in simulation software package ( RTU emulator): (2 Licenses ) RTU Programming to mapping all Analog inputs, Digital Inputs Points in RTU to allow SCADA Hosts (DNP3 and Modbus ) to communicate RTU Program interlock Logic to allow SCADA Host ( DNP3 and Modbus) to send control command as per attached interlock Logic program Two (2) configuration Laptop Two (2) MOXA Modbus gateway MB3170 Full engineering will include as minimum (FDS, detailed engineering, testing procedures, time schedule, execution plan, documentation, procurement plan according to world bank conditions. Full testing services (FAT: (FAT attended by (No. 3 Gasco persons)at the original manufacturer certified premises (factory). Full testing services (SAT, provisional acceptance), Full construction (installation, pre-commissioning, commissioning, site acceptance, startup, provisional acceptance) Full training services for RTUs (for : (4) GASCO persons) Full documentation

110 3.2.1 Preliminary BOM Ser. Item QTY Technical Specification Commodities 1 RTUs 9 Section G Digi router: DIGI Transport WR21. 3 SMART Transmitter Power Supply Analog Safety Barriers 9 Section Section MOXA Modbus gateway Section Configuration laptop 2 Section Software tools for RTU 2 Section Fluke 715 Volt/mA Calibrator 2 Section Services that includes at least but not limited to: Site survey FDS, Detailed engineering Programming and configuration of RTUs FAT, shipping, mobilization, storage Training, documentation Installation of RTUs inside the communication shelter Feeding RTUs with 24 VDC power from telecom rectifier source Connecting terminated instrumentation signals to the isolated inputs of RTU including all (cables, accessories, terminations and relevant materials). Each terminated signal inside the RTU cabinet should labeled with legend or marker with a high grade Head shrink cable labels or equivalent, including field instrumentation signals, Power cables and interconnection wires inside RTU cabinet.

111 3.3 Goods and Related Services in details RTU specifications Item Specification 1- RTU type Small size RTU 2- Memory 64 MB or more 3- Protocols and Interface ports Two active working IEEE standard, 10/100 fast Ethernet polling ports: 1-Two different IP addresses, One interface Configured with an IP address and gateway 1 (network 1), the other interface Configured with another IP address and gateway 2 (network 2). Example: Network 1 ( X) Network 2 ( X) 2-Each port is equipped with (MODBUS TCP and DNP3 TCP) actively working simultaneously as slave (server) drivers One active working serial RS232 or RS485 polling port. The port is equipped by (MODBUS RTU slave protocol) Programming and configuration port(dedicated or shared with the Ethernet ports) 4- Sizing of Input / output Channels 6 analog inputs 8 digital inputs 4 digital outputs Analog input Input type: differential (CH+ / CH- for each analog input) Ranges: (4-20 MA) Sinking (loop Excitation from power supply safety barrier).

112 Resolution: 13 bits (12 bits plus sign). Calibration for all channels Refer to Figure (5) in Drawings section 4.2- Digital Input Loop voltage: 24 VDC Dry contact Normally open contact Test / Normal selector switch should be installed and connected to one of the Digital input channels Refer to Figure (6) in Drawings section 4.3- Digital Output Relay output type Wired to Supply the valve actuator with 24 2 AMP per each digital output point, when the command is issued Relays Rating can be achieved by external relays if internal RTU relays does no fulfill such current rate. Normally open contact Refer to Figure (7) in Drawings section 4.4- For all above modules 4.5- Isolation Loop voltage: 24VDC Typical AI,DI, DO wiring is below All communication ports should be isolated from each other and all IO points

113 5- Firmware User friendly software with windows menu driven to perform (RTU configuration, programming and troubleshooting) Support the Standard IEC compliant programming languages with minimum: 1-Relay ladder logic programming. 2-Functional block diagram 3-Structured Text Web server for Remote configuration, remote diagnostics. Saving configuration in non-volatile RAM or flash 6- Software licenses No. (2) Software to be installed on laptops for full programming functionality 6AI,8DI,4DO including ladder logic,functional block, Modbus,DNP3 etc The software license should cover the RTU simulation mode for programming and development of logic programs and configuration ( RTU Hardware emulation) Support online debugging / simulation and configuration 7- Environmental conditions 8- Power supply Relative humidity: 10% to 95%, no condensation Ambient temperature: (0 to 60) 0C RTU will accept DC power source (24 VDC) 9- Wiring of Input / Output Signals 10- Enclosure Specs. Wiring of all analog inputs / digital inputs / digital outputs signals as per section 4.1 Fused terminal blocks for analog inputs digital inputs and digital output signals Color code for power Wires AI wires DI wires and DO wires Labeling for each wires labeling for each component inside the enclosure Submitting of Wiring drawings and GA for the RTU cabinet Refer to Figure (8) in Drawings section Product or component type Compact enclosure Enclosure nominal height Enclosure nominal width 1200 mm 800 mm

114 11- Training Enclosure nominal depth Door Type Type of gland plate Installation Accessory type 300 mm Device composition Lock 1 Door 1 Body 1 Plain Standard Wall Mounting or the RTU should be installed on a base of height 50 cm above the floor Cable gland plate 2 Number of doors 1 front face Door opening side Reversible 120 degree Lock type 3 points lock, 3 mm double-bar Accessibility for operation Front Removable parts Door by hinges Cable gland plate by screws Color Grey Or any IP degree of protection IP54 Number of Attendees : (4) Four SCADA Engineers Training shall be detailed to cover all the RTU features and components, the course contents, and duration should be submitted to GASCO for approval. The training course shall be in accordance with the equipment versions, software and firmware releases offered in the quotation. The training course shall be conducted by experienced instructors qualified/certified in the subject matter of the course. Training course shall include, but not be limited to the following: Hardware modules configuration. Software and firmware configuration and development. DNP3 Protocol basics and communication in the RTU Modbus Protocol communication in the RTU Mapping of Analog input, Digital input and digital output registers to the Modbus and DNP3 ports, and test the communication by polling these registers using Modbus simulator / DNP3 simulator

115 Explain of RTU FAT Program (Interlock Logic) and Debug / Download the program User-Defined Function Blocks ( create, test, and save in library ) Maintenance 11-Factory Acceptance Testing (FAT) Guarantee GASCO Shall test 100% of Supplied RTU Enclosures GASCO Shall test 100% of Analog inputs, Safety Barriers,Digital Inputs and digital output channels DIGI WR21, Moxa MB3170 and the Laptops are included in the FAT GASCO has all rights to test any feature listed in bidder's offer. Factory Acceptance Testing will be conducted before delivery of the RTU to GASCO. RTU FAT Project downloaded in RTUs (Interlock Logic) will be tested in FAT FAT shall start after FAT procedures submitted by bidder and approved by GASCO All Test equipment, Simulators, Manuals, required to execute FAT shall be provided by bidder FAT shall be attended by (3) gasco personnel (FAT attended by (No. 3 Gasco persons)at the original manufacturer certified premises (factory). 12 month from PAC for all project's components

116 3.3.2 Digi 3G routerwr21 Model Number: WR21-U92A-DE1-TA Digi TransPort WR21 - Cellular (HSPA+ Global), Ethernet (2 Ports), Serial (1 RS-232/422/485 Port), Class 1 Division 2 (C1D2), Antennas included, Power Supply not included (International) Specs: Model: Digi TransPort WR21 Base Hardware: (2) RJ45 Ethernet, (1) DB-9 RS-232/422/485 Class 1 Division 2 (C1D2) Certified: Yes Cellular Network: HSPA+ Global (850/900/1700 (AWS)/1900/2100MHz) WiFi: Not Included Remote Management: Digi Remote Manager Power Connector: 2-pin Terminal Block (24 VDC) Power Supply: Not Included Antennas: Included (P/N: (2x)) DIN Rail mounting Kit Accessories required: 1. Antenna Base SMA, 3m, RG58 Part Number: Mounting Bracket - DIN Rail. Compatibility: WR21 Part Number: Note: Digi Router shall be installed in a DIN Rail inside RTU Enclosure

117 3.3.3 SMART Transmitter Power Supply Analog Safety Barriers Model No: KFD2-STC4-Ex1 OR Alternate Model No. MTL channel isolated barrier 24 V DC supply (Power Rail) Input 2-wire and 3-wire SMART transmitters and 2-wire SMART current sources Output 0/4 ma ma Terminals with test points MOXA Modbus gateway 3170 Model No. : MGate MB3170 Number of Ethernet Port: Two (1 IP, cascade) Protocol : Modbus TCP Number of Serial Port : One Protocols : Modbus RTU/ASCII Master/Slave Power adapter

118 3.3.5 Configuration laptop Processor : Intel core i7-7500u Processor (4M Cache, up to 3.50 GHz) Processor (or better) 8 GB DDR4 installed Storage : From 1 TB HDD or more Optical drive : DVD +/-RW (can be external drive ) Display size: From 14 / 15.6 Integrated Ethernet LAN 10/100/1000 Mbps Base-TX (RJ45) wireless LAN a/g/n (WIFI) 2 ports USB port USB HDMI port Power (AC 220/240 V frequency 50/60Hz)-input 8-cell Li-ion battery Natural Leather original carrying case Genuine Windows 10 professional Genuine Microsoft Office (latest version) 2 years warranty (from the original warranty from the original equipment manufacturer or granted from its authorized reseller and technical support in Egypt.

119 3.3.6 Engineering solution RTU communication Polling Technique Figure 1 (RTU communication Polling Technique)

120 Interlock Logic Program Close Command: The interlock logic checks that the status of the GOV is correct, and the GOV L/R is activated (remote position ) to accept the command remotely, and no other command is issued or in progress, if all conditions is true a digital output signal will be issued to supply GOV actuator with 24 VDC to close the valve. A feedback signal (the limit switch close) will reset the digital output signal and the command close considered successfully done. If no feedback received from the Limit switch, a timer is activated (on-delay timing is started ) from issuing the digital output signal for 90 seconds then the DO signal is rest and the command close considered fail to close Refer to Figure (2) Open Command: The interlock logic checks the same conditions, in addition to absolute difference value between upstream pressure and downstream pressure, is check to be less than or equal 0.5 bar (as we feed by Gas network Performance Upgrading department). For the time being, the open command is not activated in SCADA host yet. Refer to Figure (3) Close and Open Commands: RTU -L/R Selector Switch should be on to be in normal mode In cabinet maintenance purposes the RTU -L/R Selector Switch should be off, so that the digital output command is disabled (Test mode) User Defined Function Block: Refer to Figure (4)

121 Figure 2 ( Interlock Logic For Close Command)

122 Figure 3 ( Interlock Logic For Open Command)

123 Figure 4 (Customized Function for Valve Operation)

124 Typical Signal List for Sectionalizing Valve Typical GOV Sectionalizing Valve Signal List Digital Inputs Sr. CH. No. Equipment Tag Description Message / Alarm 1 DI1 XXX-LSC-GOV ( PL Name) GOV Limit Switch Close GOV Status : Close / Open / Transient / 2 DI2 XXX-LSO-GOV ( PL Name) GOV Limit Switch Open Instrument Error 3 DI3 XXX-VL/R -GOV ( PL Name) GOV Limit Switch Local/ Remote Remote / Local 4 DI4 XXX- Rectifier Alarm Rectifier Alarm Normal / Alarm 5 DI5 XXX- Shelter High T Alarm Shelter High T Alarm Normal / Alarm 6 DI6 XXX- Shelter Fire Alarm Shelter Fire Alarm Normal / Alarm 7 DI7 XXX- Shelter Door Alarm Shelter Door Alarm Normal / Alarm 4 DI8 RTU -L/R Selector Switch Cabinet Test Normal Selector Switch RTU Remote / Local Digital Output Sr. CH. No. Equipment Tag Description Message / Alarm 4 DO1 XXX-HSC-GOV ( PL Name) 24 Vdc supplied by command To Close GOV Closed / Fail to close 5 DO2 XXX-HSO-GOV ( PL Name) 24 Vdc supplied by command To Open GOV Opened / Fail to Open Analog Inputs Sr. CH. No. Equipment Tag Description Value / Units / Alarms 6 AI1 XXX-PT-PL Name Direction Pressure Upstream Bar/ (HH - LL )alarm 7 AI2 XXX-PT-PL Name Direction Pressure Downstream Bar/ (HH - LL )alarm

125 3.3.7 Fluke 715 Volt/mA Calibrator Features at a Glance: Measure loop current (0-20 ma, 4-20 ma) signals with very high accuracy of 0.015% and 1 ma resolution Measure voltage output process signals from PLCs, transmitters Source or simulate 24 ma loop current Source voltage to 100 mv or 10V 24V loop supply with simultaneous current measurement Enhanced voltage and current measure and source accuracy Improved battery life 250 ohm HART resistor with loop power Holster features test lead storage Compatible with tool pack magnetic hanging system Step and linear ramp output function Configurable zero and span settings Accessories required: 1. Standard Calibration Certificate 2. Fluke C90 Soft Case for DMM and Visual IR Thermometers o Zippered carrying case with inside pocket and belt loop o One year warranty 3. Fluke TL80A Basic Electronic Test Lead Kit

126 4. Drawings 4.1 Input / Output typical signals wiring These wiring diagrams to help the bidder to deliver the input/output modules with the proper functionality only Analog Input Typical Wiring Figure 5 (Analog Input Typical Wiring) Note: S.B is an abbreviation of Safety Barriers Power supply and Number of required Safety Barriers per RTU is (4) four

127 4.1.2 Digital Input Typical Wiring Figure 6 (Digital Input Typical Wiring) Note: one of digital inputs should be wired to Test / Normal Switch selector (RTU L/R Switch)

128 4.1.3 Digital Output Typical Wiring 2 A 2 A 2 A 2 A Figure 7 (Digital Output Typical Wiring) Note: Relays will supply the valve actuator with 24 VDC 2A when control command is issued

129 4.1.4 RTU Cabinet Preliminary GA Drawing Figure 8 (RTU Cabinet Preliminary GA Drawing)

130 5. Inspections and Tests The following inspections and tests shall be performed: [insert list of inspections and tests] 5.1. Acceptance Test The acceptance test shall demonstrate to the satisfaction of GASCO that all the supplied equipment will be extensively tested in the teasing stages (FAT, SAT, PAC, FAC). There are three levels for the acceptance test: Factory Acceptance Test "FAT" Factory Acceptance Testing will consist of detailed and extensive testing of all functional specifications of the proposed subsystems. Factory Acceptance Testing shall be conducted extensively in a sufficient period that allows full testing of all functions, features and entire system integration. Groups of (3) GASCO Engineers will attend FAT to conduct and manage the provision of FAT for all project components. The FAT will be hold in the manufacturer main office/premises/ location (any secondary premises or construction staging area/ local office will not be considered a proper/suitable and functional FAT place, and GASCO will not accept conducting FAT procedures at such places. Bidders shall submit a detailed description of FAT, simulation equipment/ software and FAT Test Facility capabilities and preparations/ arrangements to GASCO for reviewing, commenting and approval before conducting FAT procedures. FAT test procedures final approval by GASCO must be at least two month before the actual scheduled execution of FAT tests The procedures to carry out the FAT shall be well defined and documented in a proper way and each test procedures shall be described in a logical sequence (comprehensive, scheduling, objective and what criteria are being used to determine whether the outcome is satisfactory or not, results expected, results discrepancies degree of importance: major, minor,..etc.) i.e. How to test the functional items software and hardware. The satisfactory completion of the functional acceptance test on any or all the equipment in isolation from each other shall in no way release the Bidders from their ultimate responsibility to integrate all the equipment of the system and produce a working system which fully meets GASCO technical specifications detailed under this document. Upon complete satisfaction of such tests GASCO shall sign the functional (factory) acceptance test certificate "inspection certificate" and hence the FAT related payment stage dues can be released. No equipment being supplied under this project shall be shipped unless the appropriate inspection certificate has been signed by GASCO.

131 Site Acceptance Test 1. These tests are to be performed in order to verify the compliance of the different subassemblies and the successful integration of the system with respect to the equipment specifications and the technical specifications detailed under this document. 2. These test will be the real implementation of the whole system components functioning according to specification and design needs. 3. SAT will include (end to end tests, some selected FAT tests again at real sites) 4. Bidders shall furnish GASCO with a detailed SAT plan at least one month prior to the commencement of SAT for review and approval. 5. On the satisfactory completion of such tests GASCO shall sign the SAT in which the system is considered to be accepted Quality, Guarantee & Warranty 1. Bidders are responsible for guaranteeing the equipment / software / materials supplied under this project against any failure due to manufacturing, quality of materials and system design for 12 month after PAC for all project bill of materials and services.. 2. Bidders shall furnish GASCO with original guarantee & warranty certificates issued by the equipment original manufacturers covering the whole specified guarantee & warranty period. 3. Bidders shall guarantee & warrant that the supplied equipment are brand new (original /Genuine), unused, of the most recent or current models and that they incorporate all recent developments in design and materials Training Bidders shall customize (dedicated for GASCO team) a professional, detailed and extensive training programs on the operation, configuration, maintenance, troubleshooting, programming, development and administration for both hardware and software as stated in previous sections. Each training program shall be arranged for GASCO Engineers at the main manufacturer premises facility (any staging area or less prepared facility will not considered acceptable training facility for GASCO) Training for GASCO (four (4)) engineers. shall be as follows: o RTUs Configuration, troubleshooting, programming, administration and building logic "interlock as stated in drawing section. Training must be arranged before installation works in order to well prepare engineers who will have the responsibility for system maintenance, development, modification, enhancement, de-assembling & re-assembling, software configuration and troubleshooting on the delivered RTUs and ease the installation, commissioning and startup works. Bidders shall provide complete set of soft and hard copy training materials and presentations covering all the training topics for each trainee.

132 5.4. Documentation 1. Bidders shall submit the documentation for client review during manufacturing and at the final stage. 2. Bidders must advise the client of changes and modifications to documents-if any- so that documentation can be kept "current" at least until the date of system acceptance at site. 3. All documentations shall be produced in English and include the following: Functional Detailed Specifications Detailed Engineering, detailed drawings..etc. Installation and commissioning procedures, acceptance testing procedures. Site preparation, Workshop drawings, System wiring, layouts Operation, maintenance, service troubleshooting manuals Software manuals (operation, Programming, configuration, troubleshooting and service) manuals. RTUs circuit diagrams RTUs construction workshop drawings RTUs configuration and setup procedures three (3) complete original sets of soft and hard copies for operation, programming, configuration, maintenance and technical manuals covering all the sub-systems provided three (3) complete original hard copy for final Sites (RTUs) as-built attached with each RTU I/Os database (tags, loops, wiring, parameters adjustments and limits). Full IP map and scheme for whole system setup Full configuration steps and procedures of firewall with routing devices. The following inspections and tests shall be performed: The bidders shall include as part of services responsibility the following testing stages as minimum to verify, validate and approve design and construction till the commissioning and startup: Factory acceptance testing as per attached specification Site acceptance testing as per attached specification Provisional acceptance testing as per attached specification Final acceptance testing as per attached specification Note: The bidders must afford all the testing tools hardware and software during FAT, to fully test all the listed functionalities of supplied system components as per specification

133 ENGINEERING DEPARTMENT INST/01/REV1 INSTRUMENTATION TECHINCAL SPECIFICATIONS ENGINEERING DEPARTEMENT INSTRUMENTATION MATERIALS SPECIFICATIONS REV. 1 Issue Date: 1 ST JAN 2018 No. of Sheets 11

134 ENGINEERING DEPARTMENT INST/01/REV1 INSTRUMENTATION TECHINCAL SPECIFICATIONS General Specifications of Weatherproof Junction box Item Type I Type II Material ASS / PC or GRP ASS/PC or GRP Cover Solid Cover (Non Transparent) Solid Cover (Non Transparent) Shape Rectangle Rectangle Color Light Gray or black Blue Approximate Size 250 x 150 x 150 W x D x H 150 x 150 x 150 W x D x H Location Outdoor Outdoor Protection Level IP65 IP65 Area Safe Safe Mounting Wall Mounting Wall Mounting No. of Inlets 1 Gland 3/4" 2 Gland 1/2" No. of Outlets 1 Gland 3/4" 2 Gland 1/2" Accessories - Mounting Plate - Din Rail - Knife Type Terminal Strip (for 30 points) - Mounting Plate - Din Rail - Knife Type Terminal Strip (for 20 points)

135 ENGINEERING DEPARTMENT INST/01/REV1 INSTRUMENTATION TECHINCAL SPECIFICATIONS INSTRUMENT ENCLOSURE DATA SHEET Material Sealing Size Enclosure: Made of Hot-Pressed Glass Fiber Reinforced Polyester, Hardly inflammable And Self-Extinguishing. Window: Toughened Low Heat Glass ( Heat Insulation ) With A Wind Screen Type Rubber Seal Double Seal Protection. Enclosure: Approximate Expected Size 450 mm X 500 mm X 400 mm- (W x H x D) Window with Approximate Size: 250 mm X 250 mm - (W x H) Construction Two-Part Construction Split diagonally, Lower Part for Installation Of Equipment and Upper Part As Lid, The Enclosure Is Equipped With: - Mounting Hub Suitable for 2" Pipe Stand as per attached DWGs - Two 1/2" holes for PT cable gland entry and 1/2" NPT x 12mm male connector entry Color Light Grey, RAL 7032 UV-Resistance

136 ENGINEERING DEPARTMENT INST/01/REV1 INSTRUMENTATION TECHINCAL SPECIFICATIONS INSTRUMENT ENCLOSURE DWG

137 ENGINEERING DEPARTMENT INST/01/REV1 INSTRUMENTATION TECHINCAL SPECIFICATIONS ELECTRONIC TRANSMITTER DATA SHEET Tag Installation service Fluid Operating pressure Operating temperature Design pressure Design temperature Calibration span Calibration stability Accuracy Repeatability Sensitivity Linearity Output signal Power supply Electrical housing type Mechanical protection Ambient temperature Humidity Tropicalization Electrical connection Process connections Diaphragm material Field / Inside Enclosure Gauge pressure monitoring Natural gas From 7 to 70 bar (g) From 0 to 24 C 70 Bar (g) 70 C barg Six months minimum +/- 0.1% of full scale +/- 0, 1% of full scale +/- 1% of full scale +/- 0.1% of full scale 4 to 20 rna (two wire system) + HART 24V dc Ex ia IIB T3 IP 65 according to BS C 20% 50% Required 1/2" NPT (F) Complete with its suitable EEX d cable Gland. 1/2"NPT (F) (ANSI B2.1) AISI 316 L

138 ENGINEERING DEPARTMENT INST/01/REV1 INSTRUMENTATION TECHINCAL SPECIFICATIONS Process connection side material Bolt material Gasket material Liquid filling type Local readout Local readout scale Accessories Electronic housing and cover AISI 316 L Carbon steel Viton Silicon oil Required 4 20 ma Mounting kit (2 S.S brackets + L-shaped support) suitable for mounting i n s i d e side of 2" vertical pipe. Stainless steel nameplate Low copper content aluminum alloy or aluminum alloy or die cast aluminum Note: Each Transmitter shall be provided with test certificates and calibration certificates

139 ENGINEERING DEPARTMENT INST/01/REV1 INSTRUMENTATION TECHINCAL SPECIFICATIONS PRESSURE GAUGE DATASHEET Tag Location Type Service Fluid Range Bourdon Pressure indicator Natural gas barg Accuracy +/-1% Operating temperature From 0 C to 45 C Dial size and type 150mm - Glycerin filled Dial material Dial colour Aluminums Black graduation o n white background Case Weather proof, heavy duty aluminum with Low blowout disc filled with damping liquid Pointer type Oxidized aluminum, adjustable index pointer balanced Pointer colour black Movement Stainless steel with zero and over pressure stops Housing material Stainless steel Windows material Safety glass Amplifying device Material Stainless steel Bourdon material Process connection Material Process connection size Allowed over range Overpressure p r o t e c t i o n Process fluid temperature Ambient temperature Stainless Steel AISI-316 Stainless Steel AISI-316 1/2" NPT-M ANSI B2.1 (Radial) 1.5 times of reading Design pressure -20 to +65 C 20 to +65 C Degree of protection IP65 in accordance with ANSI B Note: Each Pressure Gauge shall be provided with test certificates and calibration Certificates.

140 ENGINEERING DEPARTMENT INST/01/REV1 INSTRUMENTATION TECHINCAL SPECIFICATIONS Specifications of Stainless Steel Tubing, Fittings and Manifolds A) S.S Tubing: Material: Fully Annealed high quality type 316 seamless Stainless steel - ASTM A269 IP316. Size: 12 mm and wall thick (up to 1.5 mm could be accepted) - Surface finish: Finished tubes shall be reasonably straight and have smooth Ends free of burrs provided that a smooth curved surface is maintained. B) Tube Fittings: - Stainless Steel AISI 316, Forged according to ASTM A182. Double Ferrule. - Pressure Rating 3000 PSI. It will include Male Connectors (1/2" NPT x 12 mm T.C), Intermediate Union (12 mm T.C both ends) and Hex Nipple (1/2" NPT male from both sides) - short. C) Gauge Root (Valve) Manifolds: - One Piece body of vertical style. - Construction: of S.S psi Pressure Rating: 3000 PSI (at 20 C). - Gauge Root Valve should be SS316L Inlet: 1/2" NPT-M, outlet: 3 X 1/2" NPT-F according to BS , werkstoff , Plus Vent plug 1/2" NPT-M, SS316L, Plus Hex plug, 1/2" NPT-M, SS316L. D) PT (2-Valve) Manifolds: - One Piece body of vertical style. - Construction: of S.S psi Pressure Rating: 3000 PSI (at 20 C); - 1/2" NPTF inlet, outlet and vent connections - One block valve + one bleed / PT-calibration valve.

141 ENGINEERING DEPARTMENT INST/01/REV1 INSTRUMENTATION TECHINCAL SPECIFICATIONS Mounting Material Specs.

142 ENGINEERING DEPARTMENT INST/01/REV1 INSTRUMENTATION TECHINCAL SPECIFICATIONS 1- GOVs And Instrumentation Cables Specs. All cables shall have an insulation rated at V rms to earth as a minimum, and shall be capable of withstanding an a.c. test voltage of 1 KV min. Intrinsically safe circuit cables shall conform to BS Each I.S. circuit shall use cores forming a twisted par or triplet. Flameproof, general purpose alarm and power supply cables shall conform to BS 6234, laid with a non-hygroscopic filler and PVC extruded bedding. Overall Cable Sheath Colors shall be as follows: Flameproof: Intrinsically safe: Black Blue 2 CABLING SYSTEM 2.1 Intrinsically Safe System 4-20mA and Alarm Signals Cables for I.S. system shall be specifically designed for I.S. circuits and shall conform to BS Cables shall also have a suitable L / R Ratio that should not exceed 25 mh / ohm and maximum mutual capacitance value to conform to the I.S. hazardous area certification for the apparatus. Cables shall conform to BS 5308 (PE / PVC) with 0.75mm2 (24xO.2) plain annealed copper conductors, insulated in PE and laid in twisted pairs or triples. An aluminium laminated collective screening tape and drain wire shall be provided over a non-- hygroscopic binder tape, this shall be covered with an extruded PVC compound. Conforming to BS 6746 type 6 and Galvanised round steel wire braid armour with an overall extruded PVC turquoise sheath conforming to BS 6746 type 6. Cables shall be tested as detailed in BS Cable core colours shall be as described in BS 5308 for 2 wire system.

143 ENGINEERING DEPARTMENT INST/01/REV1 INSTRUMENTATION TECHINCAL SPECIFICATIONS 2.2 Flameproof and General purpose 4-20mA signals Cables for flameproof analogue circuits shall conform to BS 5308 except that the requirements for L/R ratio and maximum mutual capacitance are dismissed and the overall extruded PVC sheath shall be black in colour and conform to the requirement of BS Alarm and Power Supply 24V D.C. Signals Cables for alarm and power supply system 24Vdc shall conform to BS 5308 except that the requirements for L/R ratio and maximum mutual capacitance are dismissed and the overall extruded PVC sheath shall be black in colour and conform to the requirement of BS Multi-pair cables have a collective screen only. 2.3 Conductor size The minimum conductor size for analogue cables to BS 5308 or BS 6346 shall be 0.75 mm2. The minimum conductor size for alarm and power supply cables to BS 6346 shall be 1.5 mm2. 3 CABLE CHARACTERISTICS Conductor material: Conductor size Insulating material Screen material Bedding Armour Outer Jackets Test voltage Plain annealed bare copper (See cable list) 300/500 V PE Aluminum Mylar foil PE Galvanized round steel wire braid/ Steel Wire armored. According to BS code (PVC) 600/ 1000 V 4 CABLE TYPES REQUIRED Item Description Service 1 12 x 1.5 mm2 Braid/ Wire Armored Govs To Control Panel 2 2 x 0.75 mm2 Braid/ Wire Armored Transmitters to Closure J. Box + Screen + Shield

144 Page 1 of 3 Egyptian Natural Gas Co. G A S C O Gen. Dept. of Engineering Affairs Material Requisition Project name: RAVEN / W.D.G.C Gas Pipeline Project Material Specs. no. Project no. INST/01 Instrumentation materials Specs. rev. Requisition no. INST/01/REV Material Requisition Status Rev. no. Date Revisions Originator Approval 0 5/02/2018 Issue for Tender