Contract File Reference Page

Number: P1007 1007-DISQ-0-M-SS-42026-Rev.3 1 of 13

RWE Dea

Disouq Field Development

Division 15 Mechanical Works

SPECIFICATION FOR VALVES

1007-DISQ-0-M-SS-42026

3 04.09.13 Issued for Construction T Omara A Fawzi A Hamdan RWE

2 17.06.13 Issued for Client Review T Omara A Fawzi A Hamdan RWE

1 02.06.13 Issued for Client Review T Omara A Fawzi A Hamdan RWE

0 03.07.12 Issued for Client Review H Karam A Fawzi A Hamdan RWE

Rev Date Description Issued By Checked Approved Client

By By Approval
 Onspec Engineering Solutions
Disouq Field Development Project
Specification For Valves

Table of Contents

1 GENERAL ................................................................................................................5
1.1 Scope .......................................................................................................................5
1.2 Referenced Documents ............................................................................................5
1.3 Codes, Standards and Regulations ..........................................................................5
1.4 Terms & Definitions ..................................................................................................5
1.5 Abbreviations ............................................................................................................6
1.6 Submittals .................................................................................................................6
1.7 Quality Assurance.....................................................................................................6
1.8 Delivery, Storage and Handling ................................................................................6
2 PRODUCTS .............................................................................................................7
2.1 Manufacturers...........................................................................................................7
2.2 Valve Features, General ...........................................................................................7
2.3 Material and Marking ................................................................................................7
2.4 Gate Valves Inside Buildings ....................................................................................8
2.4.1 Gate Valves 50 mm and Smaller ..............................................................................8
2.5 Gate Valves Outside Buildings..................................................................................8
2.5.1 Gate Valves, 65 mm and Larger ...............................................................................8
2.6 Globe Valves ............................................................................................................9
2.7 Check Valves ............................................................................................................9
2.8 Float Valves ..............................................................................................................9
2.9 Butterfly Valves .......................................................................................................10
2.10 Ball Valves ..............................................................................................................10
2.11 Stop Valves ............................................................................................................10
2.12 Drain Cocks ............................................................................................................10
2.13 Surface Box Assemblies .........................................................................................10
2.14 Identification Labels ................................................................................................11
3 EXECUTION...........................................................................................................11
3.1 Examination ............................................................................................................11
3.2 Valve Ends Selection ..............................................................................................11

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Specification For Valves

3.3 Valve Installations ...................................................................................................11

3.3.1 General Application ................................................................................................11
3.3.2 Threaded Connections ...........................................................................................12
3.3.3 Flanged Connections ..............................................................................................12
3.4 Field Quality Control ...............................................................................................12
3.5 Adjusting and Cleaning ...........................................................................................12
4 FIRE HYDRANTS ...................................................................................................13

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Specification For Valves

Changes List
Date
Rev. prepared Prepared by Description
(DD.MM.YYYY)
Section 1 (General) , Item 1.3 ( Codes , standards
01 02.06.13 T Omara
and regulations)
01 02.06.13 T Omara Section 4 ( Fire hydrants )

02 17.06.13 T Omara Section 4 ( Fire hydrants )

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Specification For Valves

1 GENERAL

1.1 Scope
This specification includes the following general duty valves common to most mechanical
piping systems.

Gate Valves
Globe Valves
Check Valves
Float Valves
Butterfly Valves
Stop Valves
Drain Cocks
Ball Valves

Extent of each type of valves and nominal diameters shall be as shown on Drawings.

1.2 Referenced Documents

1007-DISQ-0-M-SS-42018 Specification for Basic Mechanical Materials & Methods

1.3 Codes, Standards and Regulations

Unless otherwise directed, the work of valves shall be performed in accordance with the
stipulations of the specifications indicated herein below:

ASTM American Society for Testing and Materials

A27 Specification for Steel Castings, Carbon, for General Application

B 584 Specifications for Copper Alloy Sand Castings for General Application

5752 Metal Valves for use in Flanged pipe systems, Face- to Face and Centre- to - Face
Dimensions
2531 Ductile Iron Pipes, Fittings and Accessories for Pressure Pipelines
161-1 thermoplastic pipes for the conveyance of fluids. Nominal outside diameters and
nominal pressures -metric series

AWWA M17 American Water Works Association M17 Fire hydrants

1.4 Terms & Definitions

COMPANY RWE DEA Nile Branch
CONSULTANT ONSPEC ENGINEERING SOLUTIONS

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Specification For Valves

CONTRACTOR Appointed Construction Contractor by RWE Dea

1.5 Abbreviations
ASTM American Society for Testing and Materials
BS British Standard
DIN Deutsches Institut fr Normung
EPDM ethylene propylene diene monomer
ISO International Organization for Standardization

1.6 Submittals
Submit the following:
Product data, including body material, valve design, pressure and temperature classification,
end connection details, seating materials, trim material and arrangement, dimensions and
required clearances and installation instructions.

1.7 Quality Assurance

Provide valves, where possible, from a single approved source.

1.8 Delivery, Storage and Handling

1.8.1 Preparation for Transport
Prepare valves for transportation as follows:

o Ensure valves are dry and internally protected against rust and corrosion.
o Protect valve ends against damage to threads, flange faces, and weld-end
preps.
o Set valves in best position for handling. Set globe and gate valves closed to
prevent rattling; set ball and plug valves open to minimize exposure of frictional
surfaces; set butterfly valves closed or slightly open; and block swing check
valves in either closed or open position.

1.8.2 Storage
Use the following precautions during storage:

Do not remove valve end protectors unless necessary for inspection; then reinstall for
storage.

Protect valves from weather. Store valves indoors. Maintain valve temperature higher than the
ambient dew point temperature. If outdoor storage is necessary, support valves off the pavement
in watertight enclosures.

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Specification For Valves

1.8.3 Handling
Use a sling to handle valves whose size requires handling by crane or lift. Rigid valves to
avoid damage to exposed valve parts. Do not use hand wheels and stems as lifting or rigging
points

2 PRODUCTS

2.1 Manufacturers
Subject to compliance with requirements of this section, provide products by one of the
attached list of manufacturers or approved by Company.

2.2 Valve Features, General

2.2.1 Valve Design
Rising stem or rising outside screw and yoke stems.

Non-rising Stem Valves may be used where headroom prevents full extension of rising stems.

2.2.2 Pressure and Temperature Ratings

As required to suit system pressures and temperatures.

2.2.3 Sizes
Same size as upstream pipe, unless otherwise indicated.

2.2.4 Operators
Provide the following special operator features:
Hand wheels, fastened to valve stem, for valves other than quarter tum.
Lever handles on quarter-tum valves 150 mm and smaller, except for plug valves.
Provide plug valves with square heads; provide one wrench for every 10-plug valve.
Chain-wheel operators for valves 65 mm and larger, installed 1800 mrn or higher
above finished floor elevation. Extend chains to an elevation of 1500 mrn above
finished floor elevation.

2.3 Material and Marking

Bronze valves used with the domestic cold and hot water system shall be resistant to
dezincification. Under no circumstances shall "Duplex" brass fittings be used. Cast iron
valves used with domestic cold and hot water system shall be lined. Each valve shall be
marked with east-on lettering giving the following information:

Manufacturer's Name or Trade Mark

Size of Valve
Guaranteed Working Pressure
International Standard Reference

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2.4 Gate Valves Inside Buildings

2.4.1 Gate Valves 50 mm and Smaller

Class 125, body and union bonnet of ASTM B 62 cast bronze; with threaded ends, solid disc,
copper-silicon alloy stem, bronze packing gland, "Teflon" impregnated packing and malleable
iron hand wheel.

Gate Valves, 65 mm and Larger: Class 125, cast iron body, bronze mounted, with body and
bonnet conforming to ASTM 126 Class B; with flanged ends, "Teflon" impregnated packing
and two-piece packing gland assembly, solid wedge type gate-high tensile forged bronze
spindle engaging a gunmetal nut at the top of the gate, cast iron spindle caps and hand
wheels.

2.5 Gate Valves Outside Buildings

2.5.1 Gate Valves, 65 mm and Larger

Type: Resilient seated, non-rising stem, operated by hand wheels, and closing clockwise with
direction of operation clearly casted on the hand wheel.

The nominal operating torque of closure and opening shall be appropriate for manual
operation using T- Key. All valves shall be provided with extension spindles

The valve shall be designed for no leakage under flow from either direction at a differential
pressure across the gate of 10.1 times the rated working pressure. The valve shall be capable
of being operated under the maximum unbalanced pressure that may occur.

Face to Face Dimensions shall conform to ISO 5752 I 15.

Buried Valves shall have Spigot and Socket ends, whereas valves inside different structures
shall be flanged.

When connected to Ductile Iron Pipes, Flanged and socketed ends shall conform to ISO 2531

When connected to UPVC Pipes, socketed ends shall conform to ISO 161-1. Material: Shall

be as follows:

The valve Body, Bonnet, and wedge body shall be Ductile Iron to DIN 1693
-GGG40/50.

The wedge shall be completely encapsulated with an EPDM rubber. The rubber
coating thickness shall be a minimum of 2 mm on the flow surfaces and 4 mm on
sealing surfaces.

The stem (spindle) shall be Stainless steel316 L to DIN 17400- 1.4028. The stem nut shall be
of resistant Brass, CZ 132 to BS 2872 forged integral with the wedge. Pins, clamps, screws
and other means of attachment are not acceptable.

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All Sealing rings of the bonnet and the stem shall be of EPDM with outside plastic bearings.

The Bonnet bolts shall be of Stainless steell.4401. Nuts, bolts, and washers for Flanges shall
be of high tensile steel, hot dipped galvanized to BS 729.

The valve Body and Bonnet shall be internally and externally coated with non- toxic fusion
bonded epoxy powder coat with a minimum dry film thickness of 250 micron.
Rating: Shall be as follows:
Working pressure 16 bars
Body test pressure equals to 1.5 working pressure

2.6 Globe Valves

Globe Valves, 50 mm and Smaller: Class 125; body and screwed bonnet of ASTM B 62 cast
bronze, with threaded ends, replaceable composition disc, copper-silicon alloy stem, bronze
packing gland, "Teflon" impregnated packing and malleable iron hand wheel.

Globe Valves, 65 mm and Larger: Class 125; cast iron body and bolted bonnet conforming to
ASTM A 126, Class B; with outside screw and yoke, bronze mounted, flanged ends and
"Teflon" impregnated packing and two piece backing gland assembly.

2.7 Check Valves

Swing Check Valves 50 mm and Smaller: Class 125; cast-bronze body and cap conforming to
ASTM B 62; with horizontal swing, Y-pattern and bronze disc and having threaded ends.
Provide valves capable of being reground while the valve remains in the line.

Wafer Check Valves 65 mm and Larger: Class 125; cast iron body, to ASTM A-126 Class (B)
flanged ends with replaceable bronze seat and non slam design lapped and balanced with
bronze flabbier and stainless steel trim and torsion spring. Provide valves designed to open
and close at approximately 3 kPa pressure. Provide valves capable of being refitted while the
valve remains in the line.

Check Valve with Controlled Closing: Class 125, cast iron body to ASTM A-126 Class (B),
flanged ends ductile iron disc provided with a bronze seat ring. The body shall be two-piece,
the seat set on a 55 angle. Each body half must have an access cover whole. The disc pivot
pins and bushing shall be in stainless steel.

The valve shall be equipped with a device designed to allow the valve to open fully without
interference and to close freely for approximately 90% of its strike, and final control speed of
closing through the last 10% of closing.

2.8 Float Valves

Float valves shall be of the elbow type, installed at the end of the inlet pipe, totally closed
when the float is at the end of its travel. The valve shall be able to connect an extension pipe
to its outlet.

Valve shall have flanged end conforming to ISO 2531, and shall be able to connect an
extension pipe to its outlet.

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Material: Shall be as follows:

The valve body shall be Ductile Iron to DIN 1693-GGG 40/50.

Valve disc, seat, guides and piston holder shall be of gunmetal.

The valve lever shall be of stainless steel or brass, and the float shall be of stainless steel
conforming to ASTM A 240 T 304. Liner and pins shall be of bronze, with synthetic rubber
face and seal.

2.9 Butterfly Valves

Butterfly Valves 65 mm and Larger:
Rated for 850 kPa, cast-iron body conforming to ASTM A 126, Class B. Provide valves with
field replaceable EPDM sleeve, nickel-plated ductile iron disc, stainless steel stem, EPDM 0-
ring stem seals and lever operators with locks. Provide lug or wafer type as indicated.

Drill and tap valves on dead-end service additional body strength. Provide, for insulated
valves, a long neck feature.

2.10 Ball Valves

Ball Valves 25 mm and Smaller: Rated for 850 kPa; two-piece construction; with bronze
body conforming to ASTM B 62, standard (or regular) port, chrome-plated brass ball,
replaceable "Teflon" or "TFE" seats and seals, blowout-proof stem, and vinyl-covered steel
handle with threaded ends.

Ball Valves 35 mm to 50 mm: Rated for 850 kPa; 3-piece construction; with bronze body
conforming to ASTM B 62, conventional port, chrome- plated brass ball, replaceable
"Teflon" or "TFE" seats and seals, blowout proof stem and vinyl-covered steel handle with
threaded ends.

2.11 Stop Valves

Stop valves shall be screw down pattern, with chrome plated gunmetal bodies and screwed
connections.

2.12 Drain Cocks

Drain cocks shall be plug type with hose union connector, loose key and gunmetal body.

2.13 Surface Box Assemblies

Heavy duty ductile iron surface box assemblies comprising the following parts:
Surface box cast in ductile iron with chain.
Protection tube in PVC
Extension stem
Galvanized steel square rod with operating and protection cap

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Key operating wrench

2.14 Identification Labels

All stop valves shall be provided with white plastic identification labels indicating in black
lettering the number and duty of the valve.

3 EXECUTION

3.1 Examination
Examine valve interior through the end ports, for cleanliness, freedom from foreign matter and
corrosion. Remove special packing materials, such as blocks used to prevent disc movement
during shipping and handling.

Actuate valve through an open-close and close-open cycle. Examine functionally significant
features, such as guides and seats made accessible by such actuation. Following
examination, return the valve closure member to the shipping position.

Examine threads on both the valve and the mating pipe for form (i.e., out-of round or local
indentation) and cleanliness.
Examine mating flange faces for conditions which might cause leakage.
Check bolting for proper size, length and material. Check gasket material for proper size,
material composition suitable for service and freedom from defects and damage.

Prior to valve installation examine the piping for cleanliness, freedom from foreign materials
and proper alignment.

Replace defective valves with new valves.

3.2 Valve Ends Selection

Select valves with the following ends or types of pipe/tube connections:
Pipe Sizes 50 mm and Smaller Threaded
Pipe Sizes 65 mm and Larger: flanged.

3.3 Valve Installations

3.3.1 General Application

Use gate, ball and butterfly valves for shut-off duty; globe and butterfly for throttling duty.
Refer to piping system specification sections for specific valve applications and arrangements.

Locate valves for easy access and provide separate support where necessary. Provide
dielectric insulation for connecting bronze valves with steel piping.
Install valves and accessories for each fixture and item of equipment arranged to allow
equipment removal without system shutdown. Unions are not required on flanged devices.

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Install three-valve bypass around each pressure-reducing valve using throttling-type

valves.

Install valves in horizontal piping with stem at or above the centre of the pipe. Install valves in

a position to allow full stem movement.

Install swing check valves for proper direction of flow, horizontal position with hinge
pin level.

Provide surface box assemblies for operating buried valves with T-handled key.

3.3.2 Threaded Connections

Note the internal length of threads in valve ends and proximity of valve internal seat or wall, to
determine how far pipe should be threaded into valve.

Align threads at point of assembly.

Apply appropriate tape or thread to the external pipe threads (except where dry seal threading
is specified).

Assemble joint, wrench tight. Wrench on valve shall be on the valve end into which the pipe is
being threaded.

3.3.3 Flanged Connections

Align flange surfaces parallel.

Assemble joints by sequencing bolt tightening to make initial contact of flanges and gaskets
as flat and parallel as possible. Use suitable lubricants on bolt threads. Tighten bolts gradually
using a torque wrench.

For dead-end service, butterfly valves require flanges both upstream and downstream for
proper shutoff and retention.

3.4 Field Quality Control

Testing:
After piping systems have been tested and put into service,before final adjusting and
balancing, inspect valves for leaks. Adjust or replace packing to stop leaks; replace valve if
leak persists.

3.5 Adjusting and Cleaning

Cleaning: Clean mill scale, grease and protective coatings from exterior of valves and
prepare valves to receive finish painting.

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4 FIRE HYDRANTS

Fire hydrants should be installed according to the instructions approved by the

manufacturer and matching measurements AWWA C503.

Hydrants with 2 way outlet with body fabricated from smls BE sch.40 pipe 4" according
to ASTM A106 Gr.B.

High pressure wet barrel hydrant with 4" flanged inlet or 4" NPT threads.

Rated working pressure 160PSI and test pressure at 240PSI.

Replaceable nozzle outlets - 4" - 2 1/2", stem nuts and stem seals.
Fusion bonded epoxy inside and out, and then top coated as per
customer request and approval data sheet.

There must be well-proven hydrant base and drop-resistant ground using concrete
blocks as shown in the contract drawings or approved any details.

Contractor shall be followed approved data sheet for fire hydrant before supplying
and installation.

Testing and installation

Hydrants should be tested hydrant hydrostatic pressure before backfilling. The test
must be performed on a pressure of 1.5 MPa for at least one hour and not to allow any
water leak from hydrants or pipes feeding him.

Backfilling and cleaning hydrants

After the success of the hydrostatic test, backfilling and compacting for the region is a
must. The hydrants must be free from any strange material and visible parts should be
re-painted if necessary. The contractor must obtain from the supplier the final paint for
hydrant without any additional costs for this purpose.

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