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Manufacture, Supply and Delivery of Mechanical Valves for the NMPP Project

SCOPE OF WORK

Table of Contents

1. Description of the Works.....................................................................................................

2. Engineering.........................................................................................................................

3. Quality.................................................................................................................................

4. Administration.....................................................................................................................

5. Applicable Codes and Standards.........................................................................................

6. List of Attachments.............................................................................................................

7. Bid Requirements................................................................................................................

8. Abbreviations and Definitions.............................................................................................

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1. Description of the Works

1.1 Background

1.1.1 Petroleum Products are transported by the NMPP trunk line from the Coastal Terminal at Island View in Durban to the Inland Terminal in Heidelberg.

1.1.2 This tender defines the requirements regarding the engineering, manufacturing, inspection, supply, and delivery of mechanical valves that will be required at the coastal and inland terminals.

1.2 Description of the Works

1.2.1 The scope encompasses the complete design, supply of materials, manufacturing, assembly, inspection, testing, painting, documentation, preparation for shipment (including final packaging) and delivery to Transnet warehouse, NMPP Coastal Terminal, Bayhead, Durban. All in accordance with the requirements, standards, codes and specifications as referenced in this Scope of Works

1.2.2 This amount of valves, the type, as well as the requirements datasheet is given in the table below:

# Valve Type Location Item Code Size Valve

Rating Datasheet Sheet # QTY

Swing Check Valves

1 Swing Check TM2 5163450 1” 150# 2684358-E-TM1-PI-DS-002_02 2
















17 Swing Check TM1 5163450 2 " 150# 2684358-E-TM1-PI-DS-002_02 5



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23 Swing Check TM1 5163450 16" 150# 2684358-E-TM1-PI-DS-002_02 21

24 Swing Check TM1 5163450L (with

lock mechanism) 16" 150# 2684358-E-TM1-PI-DS-002_02 4




Lift Check Valves

28 Lift Check TM1 RBD 140 1" 150# 2684358-E-TM1-PI-DS-002_03 2

Wafer Check Valves

29 Wafer Check TM2 VWCK 150CS 3” 150# 2684358-E-TM1-PI-DS-001_08 8




33 Wafer Check TM1 VWCK 150 2" 150# 2684358-E-TM1-PI-DS-001_05 1



Ball Valves

36 Ball TM2 5300959SG 6” 150# 2684358-E-TM1-PI-DS-002_27 1




40 Ball TM2 5301380 16” 600# 2684358-E-TM1-PI-DS-002_29 1


42 Ball TM1 5300959SG 16" 150# 2684358-E-TM1-PI-DS-002_27 8

Gate Wedge Valves

43 Gate Wedge TM2 5156080 2” 150# 2684358-E-TM1-PI-DS-002_15 29





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51 Gate Wedge TM2 5156080G 16” 150# 2684358-E-TM1-PI-DS-002_17 12



54 Gate Wedge TM2 SKD133G 18” 600# 2684358-E-TM1-PI-DS-002_32 2

55 Gate Wedge TM1 5156080 2" 150# 2684358-E-TM1-PI-DS-002_15 9





Globe Valves

60 Globe TM2 5160442 2” 150# 2684358-E-TM1-PI-DS-002_18 8

61 Globe TM2 5160442 3” 150# 2684358-E-TM1-PI-DS-002_18 1

62 Globe TM2 5161600 2” 600# 2684358-E-TM1-PI-DS-002_19 6

63 Globe TM1 5160442 2" 150# 2684358-E-TM1-PI-DS-002_18 7

64 Globe TM1 5160442 2" 600# 2684358-E-TM1-PI-DS-002_19 2

1.2.3 Actuators shall not be provided for any of the valves. The gearboxes, where applicable shall however be provided and shall be in accordance to NMPP 2684358-U-A00-PI-SP-003 specification.

1.2.4 Ball valves shall be full bore and shall conform to the NMPP 2684358-U-A00-PI-SP-029 specification and datasheets.

1.2.5 Globe valves shall conform to NMPP 2684358-U-A00-PI-SP-031 specification and datasheets.

1.2.6 Check valves shall conform to NMPP 2684358-U-A00-PI-SP-030 specification and datasheets.

1.2.7 Gate valves shall conform to NMPP 2684358-U-A00-PI-SP-037 specification and datasheets.

1.2.8 All gate valves shall have stellited seats and discs.

1.2.9 Ball valves 3” and smaller may be supplied as 2 piece.

1.2.10 All valves shall conform to NMPP 2684358-U-A00-ME-SP-009 for corrosion protection. The applicable System for valves at TM1 shall be System 1. The applicable system for valves at all other locations shall be System 2.

1.2.11 Some gate valves shall be delivered with stem extensions. The quantity of Gate valves that require stem extensions are noted below:

For TM2, the distances given are from the bore centreline to the centre of the hand wheel:

10” – 135cm to 150cm (3 off, item code 5156080)

14” – 135cm to 160cm (2 off, item code 5156080)

16” – 135cm (2 off, item code 5156080G)

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16” – 280cm (10 off, item code 5156080G)

20” – 285cm (2 off, item code 5156080G)

20” – 160cm to 200cm (1 off, item code 5156080G)

24” – 280cm (36 off, item code 5156080G)

24” – 193cm (4 off, item code 5156080G)

1.2.12 All pressure retaining castings shall be impact tested at -10 deg C. The minimum energy allowed for a single test is 18 Joules and the minimum average allowed is 27 Joules.

1.2.13 The Supplier shall submit a preservation procedure which will allow Transnet to safely store the valves for a period of up to 18 months.

1.2.14 All valve ends are to be flanged, unless otherwise specified.

1.2.15 Forgings in accordance to ASTM A105 are preferred to castings in accordance to ASTM A216.

1.2.16 The Supplier shall submit a shipping and packaging procedure to the Transnet Representative for review and acceptance.

1.2.17 The Supplier shall provide Transnet with the storage and handling procedures for goods prior to delivery.

1.2.18 This requirement for this scope of work falls under the Vessels Under Pressure (VUP) regulations, and not the Pressure Equipment Regulations (PER) of the OHS Act, which as of Oct 2009 replaced the Vessels Under Pressure (VUP) regulations of the same act.

1.2.19 The fabrication and completion of valves shall be staggered, i.e valves ready for shipment as they are completed. The completion of valves shall be continuous with a constant delivery and shall be in accordance with the approved manufacturing and delivery schedule that will form part of the contract.

1.2.20 The databooks and manuals shall be in accordance to NMPP 2684358-P-A00-DC-PO-005 specification.

1.3 The Supplier provides and undertakes the following:

1.3.1 The expense items required to provide the works.

1.3.2 Fabrication and assembly.

1.3.3 Quality assurance and quality control for manufacture.

1.3.4 Compliance to safety, health and environmental requirements.

1.3.5 Ensures that all applicable information and documentation is passed on to sub-supplier.

1.3.6 Ensures that Sub-suppliers comply with the requirements and referenced specifications and standards.

1.3.7 Supervision of all sub-suppliers.

1.3.8 Compliance to the law of the contract.

2. Engineering

2.1 General Requirements

2.1.1 The work is performed in strict accordance with the, specifications, standards, engineering notes and the skill and care normally used by Suppliers providing work similar to the works.

2.1.2 In the event of conflict between the codes, standards and specifications, all conflicting requirements shall be referred to the Transnet Representative for written resolution.

2.1.3 Supplier's drawings, quality documentation and engineering data submitted to the Transnet Representative shall be in English language with SI units of measurements. Text in the language of Manufacturer may be used provided the English translation is shown.

2.2 Data Requirements

2.2.1 The Supplier shall submit documents as per the applicable specifications and this Works Information.

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2.2.2 The above requirement (Sections 2.2.1) is also applicable to documents required from sub-suppliers appointed by the Supplier.

2.2.3 The Transnet Representative and Others check and provide comments to the Supplier’s document. The Supplier reviews and incorporates these comments.

2.2.4 The Supplier submits the documents to the Transnet Representative who forwards them to others for review and acceptance.

2.2.5 Acceptance or approval of his documents does not relieve the Supplier from any of his legal and contractual liabilities and responsibilities.

2.2.6 Documents shall be in reproducible form. Each submission of documents shall consist of signed documents and electronic media (CD disk) containing copies of all documents submitted.

2.2.7 Supplier shall not proceed with fabrication until notified by the Transnet Representative or on receiving at least “B” approval status for all required engineering, fabrication and quality documentation.

2.2.8 All documents which are not drawings shall be submitted with a cover sheet which is unique to description of the document, a history of revisions of the document and Transnet.

2.2.9 All drawings shall have the title block unique for this project included on the drawing, located at the lower right hand side of the drawing.

2.2.10 For documents of A4 and A3 size, the title block shall be generally measuring 180 wide x 120 high. For all drawings larger than A3 the alternative title block measuring 180 wide x 195 shall be used. Standard title blocks to be incorporated into the general arrangement drawing will be given after order placement.

2.2.11 For drawings the minimum size is A3 and the maximum size is A1. A0 size drawings may be used only after agreed to by Transnet, in which case all submissions shall be reduced to A1 size. A4 may only be used for parts lists and the like.

2.2.12 Every drawing must carry the Project document number allocated to it. Document numbers shall be obtained by the vendor from Document Control Department.

2.2.13 In addition to scanned certified “As built drawings”, complete set of updated electronic drawings in their native format (Auto CAD ver. 2004 max) shall be saved on the electronic media.

2.2.14 Each valve shall have its own Data Book. Unless otherwise specified elsewhere, 3 sets of Data Books and 2 sets of electronic media shall be supplied by the Supplier.

2.2.15 The Supplier identifies all deviations from the specifications in the proposal. Any proposed deviation which, in the opinion of the Supplier, may result in technical and/or commercial benefit to Transnet, is identified and submitted for review and endorsement. No unauthorized deviations are permitted and may result in rejection of the whole or part of Supplier’s work.

3. Quality


3.1.1 The Supplier shall comply with the quality requirements given in NMPP 2684358-P-A00-QA-PO-011.

3.2 Fabrication

3.2.1 Inspection and Testing requirements.

3.2.1.1 The Supplier submits all his procedures to the Transnet Representative for acceptance.

3.2.1.2 A pre-fabrication and inspection meeting is held at the Supplier’s works with the Transnet Representative, third party Inspection Authority and the Supplier, at least 10 working days before commencement of the Works, at which time all drawings are to have at least “B” acceptance status.

3.2.2 Chemical analysis requirements to be performed by the Supplier for Castings:

3.2.2.1 Chemical analysis shall be performed on the heat/ladle as well as the product. The product analysis shall be conducted per item cast.

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3.2.2.2 The chemical requirements for both tests shall be as per ASTM A216 WCB. In addition, the maximum allowable Aluminium content shall be 0.04%, for both tests.

3.2.2.3 Both set of results shall be presented in the valve quality databooks.

3.2.2.4 For the product, where the chemical composition is outside the requirements of ASTM A216, the Supplier may submit a concession for consideration by Transnet. The concession may only be submitted if the chemical analysis is within the tolerances of table 1 in ASTM A703/A 703M.

3.2.2.5 Both tests shall be hold points on the QCP.

3.2.3 Chemical analysis requirements to be performed by the Supplier for Forgings:

3.2.3.1 Chemical analysis shall be performed on the heat/ladle as well as the product. The product analysis shall be conducted per item forged.

3.2.3.2 The chemical requirements for both tests shall be as per ASTM A105. In addition, the maximum allowable Aluminium content shall be 0.03%, for both tests.

3.2.3.3 Both set of results shall be presented in the valve quality databooks.

3.2.3.4 For the product, where the chemical composition is outside the requirements of ASTM A105, the Supplier may submit a concession for consideration by Transnet. The concession may only be submitted if the chemical analysis is within the tolerances of tables 1 and 2 in ASTM A961.

3.2.3.5 Both tests shall be hold points on the QCP.

3.3 Delivery

3.3.1 To constitute delivery, everything required in the scope of work must be done including but not limited to:

3.3.1.1 Delivery of the goods

3.3.1.2 Submission by the Supplier and receipt by Transnet of Data books acceptable to Transnet. The Data books will include an Index, all material certificates and all other quality assurance and control related documentation required by Transnet.

3.3.1.3 Operating and Maintenance manuals

4. Administration


4.1.1 Transnet has set standards for project documentation and deliverables. The Supplier must adhere to Attachments A&B to this Works Information which details the following:

4.1.1.1 Correspondence and communications.

4.1.1.2 Drawings and document transmittals.

4.1.1.3 Instructions.

4.1.1.4 Requests for information.

4.1.1.5 Meetings.

4.1.1.6 Financial records and accounts.

4.1.1.7 Insurances.

4.1.1.8 Schedule.

4.1.1.9 Completion.

5. Applicable Codes and Standards All applicable codes and standards are listed in the valve datasheets as well as the valve specifications.

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6. List of AttachmentsThe work shall be in full accordance to the relevant sections of the following attachments forming part of the scope of work:

Attachment A Administrative Procedure

Attachment B Programming

7. Bid Requirements

7.1 Information to be Provided with Bid

The following documents shall be submitted (as a minimum) by the Bidder:

7.1.1 A check list against each requirement in this Scope of Works, with confirmation of understanding of the requirement and compliance thereof.

7.1.2 The document approval and manufacturing schedule for the complete Works. The constant staggered fabrication and completion of valves shall be visible in the schedule provided. The schedule shall be a level 4 schedule submitted in Primavera p6.

7.1.3 It is preferred that the fabrication starts from the largest bore to the smallest.

7.1.4 Supplier’s bid will be deemed to be fully in accordance with this Works, unless specifically and individually identified in a dedicated section of the bid. A comprehensive Deviation List shall be submitted with the quotation as applicable.

7.1.5 The completed form within NMPP 2684358-U-A00-PI-SP-003 specification.

7.1.6 A copy of the ISO 9001:2000 certificate, applicable to the Supplier and all sub-suppliers.

7.1.7 The Transnet Representative is under no obligation to consider, accept or discover any deviations that are not stated or declared on the Deviation List.

7.1.8 The Supplier shall provide technical information of the valves being offered that demonstrate compliance to the technical specifications of this Works Information and all attachments. This shall be done for all type of valves.

7.1.9 The Supplier shall provide a client list with quantities of valves similar to the ones in this tender, in the last 60months.

7.1.10 The Supplier shall provide a typical Quality Control Plan and sample databook for the manufacture of valves being offered in this bid.

7.1.11 Transnet reserves the right to inspect the Suppliers factory and design office during the bidding phase to ensure the Supplier is suitable to provide the Works in accordance to the requirements as set out in this document.

8. Abbreviations and DefinitionsAbbreviation DescriptionAFC Approved for ConstructionAFD Approved for DesignAFP Approved for PurchaseAIA Authorised Inspection AuthorityANSI American National Standard InstituteAPI American Petroleum InstituteASME American Society of Mechanical EngineersASTM American Society for Testing MaterialsBEP Basic Engineering PackageBOM Bill of MaterialsCCC Compressor Control CooperationCOID Compensation of Injuries and Diseases ActCP Cathodic ProtectionCWP Construction Work PackageDB Distribution BoardDC Direct CurrentDCS Distributed Control System / the DCS provide the requisite process control

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Abbreviation DescriptionDJP Durban to Johannesburg PipelineEC Electrical CompletionECC Engineering and Construction ContractEOJ End of Job EPC Engineering, Procurement and ConstructionEPCM Engineering, Procurement and Construction ManagementEW Early WarningFAT Factory Acceptance TestingFEA Finite Element AnalysisFFW Field Fit-up WeldFMEA Failure Mode and Effect AnalysisFOB Free on BoardFTA Field Terminal AssemblyFW Field WeldGA General ArrangementGRP Glass Reinforced PlasticHAZOP Hazard and Operability StudyHP High PressureHV High VoltageHVAC Heating Ventilation and Air-ConditioningIC Instrumentation CompletionIBL Inside Battery LimitIR Industrial Relations comprising all employment and labour policies, practices and procedures of the

Supplier and his sub-Suppliers pertaining to the ProjectIRM Industrial Relations Manager appointed by Transnet to co-ordinate I.R. policies, practices and

procedures of the Supplier and his sub-suppliers pertaining to the Project.IS Intrinsically SafeISA Instrument Society of AmericaISO International Standards OrganisationIso Isometric DrawingITC Indicated Total CostLP Low PressureLSD Low Sulphur DieselLV Low VoltageMaterial Goods, items or other objects or things required to Provide the WorksMAWP Maximum Allowable Working PressureMC Mechanical CompletionMCB Mini Circuit BreakerMCC Motor Control CentreMCP Motor Control Panel (Excitation panel)MDMT Minimum Design Metal TemperatureMFD Mechanical Flow DiagramMMI Man Machine InterfaceMP Medium PressureMT Magnetic Particle TestingMTTF Mean Time to FailureMTTR Mean Time to RepairMV Medium VoltageMVA Mega Volt AmpsMW MegawattNCR Non Conformance ReportNDE Non-Destructive ExaminationNDT Non-Destructive TestingNEC3 New Engineering Contract 3rd Edition Published June 2005NFPA National Fire Protection AssociationNOSA National Occupational Safety AssociationNPSH Net Positive Suction HeadOBL Outside Battery LimitOHS ACT Occupational Health and Safety Act, Act Number 85 of 1993 as amendedOTS Operator Training SimulatorPAS Plant Automation SystemP&G Preliminary and GeneralPC Practical Completion

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Abbreviation DescriptionPCS Process Control SystemPEP Project Execution PlanPFD Process Flow DiagramPID Process and Instrument DiagramPlant Mechanical items, systems or appurtenances required to Provide the Works.PLC Programmable Logic Controllerppm Parts Per MillionPQR Procedure Qualification RecordPSV Pressure Safety ValvePT Liquid Penetrant TestingPTP Production Test PlatePVP Potential Variation From PlanPWHT Post Weld Heat TreatmentQA Quality AssuranceQC Quality ControlQCP Quality Control PlanQMS Quality Management System (of Transnet)RAM Reliability, Availability and MaintainabilityRFC Ready for CommissioningRFO Ready for OperationRT Radiographic TestingSANS South African National Standards SAT Site Acceptance TestSPIR Spare Parts and Interchangeability RecordTBA To Be AdvisedTSV Temperature Safety ValveUDS User Design SpecificationULP Unleaded PetrolULSD Ultra Low Sulphur DieselUPS Uninterruptible Power SupplyUT Ultrasonic TestingV VoltsVAC Volts Alternating CurrentVIP’s Value Improvement PracticesVSD Variable Speed DriveWBS Work Breakdown StructureWPS Welding Procedure SpecificationWRC Welding Research Council

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