PETRONAS TECHNICAL STANDARDS

HUMAN FACTORS ENGINEERING – VALVE

ANALYSIS

PTS 30.00.60.13

DECEMBER 2012

 2012 PETROLIAM NASIONAL BERHAD (PETRONAS)

All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or
by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright
owner.
 PTS 30.00.60.13
December 2012
Page 2

PTS Circular
2012 - 1

PTS No: 30.00.60.13

PTS Title: Human Factors Engineering – Valve Analysis

This revision of PTS 30.00.60.13– Human Factors Engineering – Valve Analysis (December
2012) has been updated to incorporate PETRONAS Lessons Learnt, Best Practice and new
information issued by relevant industry code and standards.
The previous version of this PTS 30.00.60.13 (May 2004) will be removed from PTS binder/ e-
repository from herein onwards.
The custodian of this PTS is:
Name: M K Shrivastava
Tel. No: 03-2783 6508
Please direct any questions regarding this PTS to the above-named.

Document Approval

Revision History
 PTS 30.00.60.13
December 2012
Page 3

PREFACE

PETRONAS Technical Standards (PTS) publications reflect the views, at the time of publication,
of PETRONAS OPUs/Divisions.

They are based on the experience acquired during the involvement with the design, construction,
operation and maintenance of processing units and facilities. Where appropriate they are based on,
or reference is made to, national and international standards and codes of practice.

The objective is to set the recommended standard for good technical practice to be applied
byPETRONAS' OPUs in oil and gas production facilities, refineries, gas processing plants, chemical
plants, marketing facilities or any other such facility, and thereby to achieve maximum technical and
economic benefit from standardisation.

The information set forth in these publications is provided to users for their consideration and
decision to implement. This is of particular importance where PTS may not cover every
requirement or diversity of condition at each locality. The system of PTS is expected to be
sufficiently flexible to allow individual operating units to adapt the information set forth in PTS to
their own environment and requirements.

When Contractors or Manufacturers/Suppliers use PTS they shall be solely responsible for the
quality of work and the attainment of the required design and engineering standards. In particular,
for those requirements not specifically covered, the Principal will expect them to follow those design
and engineering practices which will achieve the same level of integrity as reflected in the PTS. If in
doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own responsibility,
consult the Principal or its technical advisor.

The right to use PTS rests with three categories of users :

1) PETRONAS and its affiliates.
2) Other parties who are authorised to use PTS subject to appropriate contractual
arrangements.
3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with
users referred to under 1) and 2) which requires that tenders for projects,
materials supplied or - generally - work performed on behalf of the said users
comply with the relevant standards.

Subject to any particular terms and conditions as may be set forth in specific agreements with
users, PETRONAS disclaims any liability of whatsoever nature for any damage (including injury or
death) suffered by any company or person whomsoever as a result of or in connection with the use,
application or implementation of any PTS, combination of PTS or any part thereof. The benefit of
this disclaimer shall inure in all respects to PETRONAS and/or any company affiliated to
PETRONAS that may issue PTS or require the use of PTS.

Without prejudice to any specific terms in respect of confidentiality under relevant contractual
arrangements, PTS shall not, without the prior written consent of PETRONAS, be disclosed by
users to any company or person whomsoever and the PTS shall be used exclusively for the
purpose they have been provided to the user. They shall be returned after use, including any
copies which shall only be made by users with the express prior written consent of PETRONAS.
The copyright of PTS vests in PETRONAS. Users shall arrange for PTS to be held in safe custody
and PETRONAS may at any time require information satisfactory to PETRONAS in order to
ascertain how users implement this requirement.
 PTS 30.00.60.13
December 2012
Page 4

TABLE OF CONTENTS
1. INTRODUCTION ........................................................................................................ 5
1.1 SCOPE........................................................................................................................ 5
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS ......... 5
1.3 DEFINITIONS ............................................................................................................. 6
1.4 CROSS REFERENCES .............................................................................................. 6
1.5 SUMMARY OF MAIN CHANGES ............................................................................... 6
2. GENERAL INFORMATION......................................................................................... 7
2.1 APPLICATION OF HFE PRINCIPLES IN DESIGN AND ENGINEERING ................. 7
2.2 GENERAL HFE PRINCIPLES RELATING TO VALVE SELECTION AND
LAYOUT ...................................................................................................................... 7
2.3 AIMS AND BENEFITS OF CONDUCTING A VALVE ANALYSIS.............................. 7
2.4 TIMING AND PROCESS ............................................................................................ 8
3. VALVES CRITICALITY ANALYSIS (VCA) ................................................................. 9
3.1 PROCESS DESCRIPTION ......................................................................................... 9
3.2 KEY STEPS IN THE PROCESS............................................................................... 11
3.3 RESPONSIBILITES .................................................................................................. 11
4. REFERENCES ......................................................................................................... 12

APPENDICES
APPENDIX A VALVE CRITICALITY ANALYSIS ................................................................... 13
APPENDIX B HFE DESIGN REQUIREMENTS FOR THE SELECTION, LOCATION
AND ORIENTATION OF VALVE OPERATORS/ACTUATORS ...................... 16
 PTS 30.00.60.13
December 2012
Page 5

1. INTRODUCTION

1.1 SCOPE
This PTS PTSspecifies requirements and gives recommendations for applying Human
Factors Engineering (HFE) principles to the operation and maintenance of valves during
project engineering. It includes the following:
• A procedure for analysing and then classifying the criticality of valves for a specific
application;
• Guidance on selection of the appropriate type of valve operator/actuator;
• HFE design requirements for the location and orientation of manual valves.
This PTS shall apply to new facilities and modifications to existing facilities; it is not
intended to apply to existing facilities that are not being modified.
This PTS shall be applied as part of an overall HFE scope of work within a project, in
compliance with PTS 30.00.60.10
This PTS is intended for use during a project’s DEFINE phase, and is followed up in the
EXECUTE phase, in conjunction with the overall approach outlined in PTS 30.00.60.10.,
where it is best executed as part of the HFE Design Analysis.
NOTE: The term “ergonomics” is used by many organisations and can be considered synonymous with
Human Factors Engineering.

This PTS should be read in conjunction with the following PTSs in so far as they cover
additional aspects of valves:
• PTS 30.00.60.10: Human Factors Engineering in Projects
• PTS 30.00.60.12: Human Factors Engineering - Investment Justification Model
• PTS 30.00.60.18: Human Factors Engineering – Design and Procurement of
Skid-Packaged Units
• PTS 30.00.60.80: Standard Form – Human Factors Engineering – Valve criticality
ratings
• PTS 30.10.05.11: Plant Model Construction and Review
• PTS 31.38.01.11: Piping - General Requirements
• PTS 32.31.00.32: Instruments for Measurement and Control
• PTS 34.28.00.31: Steel Structures

1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

Unless otherwise authorised by PETRONAS, the distribution of this PTS is confined to
PETRONAS companies forming part of PETRONAS Group and to Contractors and
Manufacturers/Suppliers nominated by them.
This PTS is intended for use in oil refineries, chemical plants, gas plants and, where
applicable, in exploration and production facilities and supply/marketing installations.
If national and/or local regulations exist in which some of the requirements may be more
stringent than in this PTS, the Contractor shall determine by careful scrutiny which of the
requirements are the more stringent and which combination of requirements will be
acceptable with regards to the safety, environmental, economic and legal aspects. In all
cases the Contractor shall inform the Owner of any deviation from the requirements of this
PTS which is considered to be necessary in order to comply with national and/or local
regulations. The Owner may then negotiate with the Authorities concerned with the
objective being to obtain agreement to follow this PTS as closely as possible.
 PTS 30.00.60.13
December 2012
Page 6

1.3 DEFINITIONS
1.3.1 General definitions
The Contractor is the party that carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of a
facility. The Principal may undertake all or part of the duties of the Contractor.
The Manufacturer/Supplier/Vendor is the party that manufactures or supplies equipment
and services to perform the duties specified by the Contractor.
The Principal is the party that initiates the project and ultimately pays for its design and
construction. The Principal will generally specify the technical requirements. The Principal
may also include an agent or consultant authorised to act for, and on behalf of, the
Principal.
The word shall indicates a requirement.
The word should indicates a recommendation.
1.3.2 Specific definitions and abbreviations

BDEP Basic Design and Engineering Package

CAPEX Capital Expenditure
Cultural validation and/or amendment of HFE design requirements by a
calibration regional HFE Specialist, to ensure that they are regionally or
culturally appropriate.
HFE Human Factors Engineering
HFE Specialist person that has achieved "skilled" or "master" competency level
for the application of HFE on PETRONAS projects, as described
in PTS 30.00.60.10
MAS Marine Advisory System
MOV Motor Operated Valve
OPEX Operating Expenditure
PEFS Process Engineering Flow Scheme
P&ID Piping and Instrumentation Diagram
PT Project Team
RVO Remote Valve Operator
VCA Valve Criticality Analysis
VMS Vessel Monitoring System

1.4 CROSS REFERENCES

Where cross-references to other parts of this PTS are made, the referenced section
number is shown in parentheses. Other documents referenced in this PTS are listed in (4).

1.5 SUMMARY OF MAIN CHANGES

This PTS has been reissued without any changes
 PTS 30.00.60.13
December 2012
Page 7

2. GENERAL INFORMATION

This is one of a series of PTSs that support the implementation of Human Factors
Engineering on projects. This PTS is concerned with all valves. The HFE design
requirements (Appendix B) with regard to location and orientation are mainly applicable to
manual valves but also apply to motorised, mobile actuator or otherwise remotely operated
valves if their expected criticality is such that they may need rapid or frequent manual
intervention either to override and manually operate them, or to visually check their status.
Accesibility requirements of instruments and their associated valves are addressed in
PTS 32.31.00.32

2.1 APPLICATION OF HFE PRINCIPLES IN DESIGN AND ENGINEERING

HFE is the process of integrating human capabilities, limitations, requirements and
expectations in the design of products, workplaces or work systems (plant/facility) resulting
in the effective, efficient, safe and healthy functioning of human beings.
The aim is to improve the efficiency of operational and maintenance task performance, to
protect operators from short or long-term health impairments, and to minimise the likelihood
of human error contributing to process safety or loss of production.
These benefits relate both to business (economics) and to quality of working life, resulting
in a reduction of the life-cycle costs of a facility, see also PTS 30.00.60.12

2.2 GENERAL HFE PRINCIPLES RELATING TO VALVE SELECTION AND LAYOUT

Valves (including those on Vendor-supplied skid-packaged units) shall be selected, located
and labelled so that they can be operated, maintained and inspected:
– with accessibility appropriate to their service;
– without exposing operators to risk of musculo-skeletal injury by requiring force to be
applied either:
• while twisting, stretching or reaching; or
• repetitively over extended periods.
Selection of valves shall take adequate account of the ability of the expected workforce to
apply and sustain the force needed to operate them. This shall include consideration of the
physical size and strength, as well as gender of the workforce.
In general, valves should be selected that have been designed in such a way as to facilitate
ease of operation and maintenance. (For example, valve handles that incorporate knurling
and other types of grip have been shown scientifically to support ease of operation.)
Actuated valves should be used where the frequency of operating them, the valve
characteristics, and the layout or work environment around the valve are such that either:
– the human operators will be exposed to unacceptable risk of musculo-skeletal injury; or
– unavoidable constraints on accessibility could mean that operators have difficulty
ensuring that valves in critical service are properly open or closed.
Specific HFE design requirements are provided in Appendix B.

2.3 AIMS AND BENEFITS OF CONDUCTING A VALVE ANALYSIS

The aim of this procedure is to ensure that all valve configurations are well designed for the
purposes of operational task performance. This is achieved by ensuring that the ease and
efficiency of use of valves identified as being most critical, as well as the risk of injury
associated with operating them, are not comprised by competing considerations in the
designing and laying out of the facility.
 PTS 30.00.60.13
December 2012
Page 8

The potential benefits from the proper application of this procedure include:
In Design:
• Reduced engineering hours (less re-work) thanks to earlier and more explicit
communications between Principal and Contractor on expectations regarding HFE and
general operability;
• More efficient approval cycle through application of an early and “right first time”
approach;
• More efficient and focused design and/or model reviews (2D and/or 3D CAD) with better
traceability of design requirements and trade-offs;
• Potential reductions in CAPEX through reduction of (permanent) steel structures as a
result of a tighter categorisation of Category-1 (Critical) valves.
In Operations:
• Improved ease and efficiency of working on the part of the Principal’s personnel (i.e. end
users in Operations);
• Reduced OPEX through reduced avoidance of modification costs to mitigate health
risks;
• Improved emergency response through quicker and more accurate identification,
access, operation and status feedback of valves;
• Fewer health problems (e.g. muscular-skeletal strain) due to operators having to adopt
awkward postures or require forces to be exerted that exceed their capabilities.

2.4 TIMING AND PROCESS

This procedure should be applied during the DEFINE phase, or as soon as PEFS or P&IDs
(even preliminary) become available for the project. This ensures that
• the results can be factored into valve procurement and piping and layout design;
• space and other design requirements needed to support critical valves (Category 1) can
be integrated into layout drawings and 3D models.
The initial classification of valves and selection of appropriate actuators may need to be
reviewed and revised when more detailed information becomes available at a later stage in
the design or implementation of a project.
 PTS 30.00.60.13
December 2012
Page 9

3. VALVES CRITICALITY ANALYSIS (VCA)

3.1 PROCESS DESCRIPTION

Figure 1 indicates the steps required.

VCA
1 No Stop
Required?

YES

PEFS
(P&IDs) Arrange
2
VCA Session

VCA Session
Review Valve
Classification and
3 Determine Criticality
Rating

Consider use of
4 MOV, RVO &
Mobile Actuators

Formalize requirements
5 and integrate in
BDEP/PS

Validate compliance
6 throughout EXECUTE
Phase

Figure 1 Flow scheme of activities for Valve Criticality Analysis (VCA)

Steps in Figure 1:
1. HFE Screening - VCA requested?
The typical point at which a VCA is requested is during the HFE Screening session
(Project Team meeting to discuss HFE scope of work required). The VCA can efficiently
be conducted as part of an HFE Design Analysis activity, or alternatively as a
standalone work scope (see PTS 30.00.60.10). For skid-packaged units, the decision to
conduct a VCA for a particular unit will be dependent upon the outcome of the HFE skid-
package screening as described in PTS 30.00.60.18. Valves on skid-packaged units
 PTS 30.00.60.13
December 2012
Page 10

shall comply with the HFE design requirements provided in Appendix B, whether a VCA
was requested or not.
2. Arrange and execute VCA session.
As soon as the PEFS (P&IDs) are available, the HFE Co-ordinator or Operations
representative in the Project Team arranges the session. On "minor" projects or where
an Operations representative has not yet been assigned to the project, the Piping and
Layout discipline or group may have to arrange the VCA session. At least the following
disciplines shall be represented at the VCA session as a minimum:
• Operations
• Maintenance
• Piping and Layout
For complex projects the following additional disciplines should also be considered:
• Human Factors Engineering
• Process Engineering
• Technical Safety
• Civil/Structural
For Vendor-supplied skid-packaged units that were identified requiring a VCA, the
Package Engineer will have responsibility for arranging the session, in consultation with
the HFE Co-ordinator or Operations representative.
3. Prepare valve list and determine criticality ranking
The VCA session shall prepare a listing or table of valve types identified on the PEFS
(P&IDS) and review the valve criticality criteria provided in Appendix A. It may be
necessary to modify the valve criticality criteria provided in Appendix A due to regional
or site specific requirements, e.g. extreme weather conditions that prevent the use of
auxiliary access equipment, thus resulting in permanent access being required. The
VCA session shall then determine and record the valve criticality rating for all the valve
types listed, utilizing the categories and classification criteria as agreed upon in the
session.
4. Consider use of MOV, RVO and Mobile Actuator.
After determining the valve criticality categories or ratings for all valves, any additional
valves requiring actuators (motorised or mobile) or remote operators shall be identified
and a method of operation selected on the basis of process engineering, economic and
HFE criteria (e.g. frequency and duration of operation, force required, speed of
activation required, etc). Guidelines for the selection of actuators for non-control valves
are provided in Appendix B.
NOTE: Depending on the availability of information on valve details and specific process conditions at the
time of the VCA session, this step may have to be postponed or reviewed during detailed
engineering as more information becomes available. Additional valves, requiring actuators, should
also be considered during HAZOP studies.

5. Formalize requirements
After completion of the VCA session the results shall be appropriately documented. The
associated access and location requirements for each valve type shall be included in the
BDEP/Project Specification and managed by the Piping and Layout discipline or group.
Deviation from the Project Specification requires the approval of Operations. Criticality
ratings of valves shall be included on PEFS (P&IDs), and if a 3D CAD model is being
used for design, Category 1 valves shall be coded therein (e.g. by colour coding 3D
shapes).
6. Validate compliance throughout the EXECUTE (Engineering, Procurement and
Construction) Phase and update VCA results and the associated access and location
requirements as necessary during design.
 PTS 30.00.60.13
December 2012
Page 11

3.2 KEY STEPS IN THE PROCESS

The early identification and classification of valves (and defining the associated design
location criteria for workspace design and layout) is the first key step in the process of
delivering effective HFE workspaces in terms of valve operation and maintenance (i.e.
ensuring that the design complies with the needs of the end user). It allows awareness to
be raised, critical valves to be identified and relevant steps to be taken to ensure that the
selection, location and layout of valves and actuators support operational requirements.
The second key step is to ensure that HFE requirements are implemented and maintained
throughout the remaining detail design and construction phases, and that any additional
valve types are properly identified and categorised. Important actions for checking and
assuring compliance with HFE requirements include:
• Assurance of HFE competence and awareness within the Project Team;
• The Engineering Contractor’s discipline engineer and/or lead piping designer shall raise
any problems or deviation requests affecting valve selection, location and layout with the
Principal (HFE Co-ordinator with support from HFE Specialist as appropriate).
Operations shall always be consulted. Auxiliary systems and Vendor-supplied package
units (skids) merit special attention in this phase;
• Formal checks during model reviews;
• A construction-phase HFE assurance plan to ensure that the requirements of this PTS
and other (non valve related) HFE design requirements are not inadvertently
compromised during construction.
The third key step takes place in the operational phase of the project, when a “valves
audit” should be undertaken to ensure that adequate steps have been taken to assure the
operational purpose of each valve. Safe systems of work for tasks requiring valve operation
should have been devised, and measures taken to ensure that non-operational valves are,
if appropriate, adequately protected from being operated by operators. For example, a hot
tap valve that shall not be used under normal operations should be protected to ensure that
it cannot be operated (e.g. removal of the valve handwheel if it is appropriate and safe to do
so). In addition, the correct procedures for all tasks shall be clearly communicated.

3.3 RESPONSIBILITES
ACTIVITIES PARTIES
Project HFE Process All PT HFE
Manager Specialist Engineer members coordinator
or
designate
1. Decide if a Valve Criticality Approve Consult Consult Execute Consult
Analysis is needed (part of
HFE Screening)
2. Arrange VCA session and Consult Consult Consult Execute
assure HFE competence
level through awareness
training, if necessary.
3. Prepare valve list, Consult Consult Consult Execute
determine and record
criticality ranking.
4. Consider use of MOV, Check Check Consult Execute
RVO and mobile
actuators.
5. Formalize requirements Approve Check Check Execute
and integrate in Project
Specification/BDEP
document.
6. Validate Compliance. Check Check Check Execute
 PTS 30.00.60.13
December 2012
Page 12

4. REFERENCES

In this PTS reference is made to the following publications:

NOTES: 1. Unless specifically designated by date, the latest issue of each publication shall be used (together
with any amendments/supplements/revisions thereof).

PETRONAS STANDARDS
Human Factors Engineering in Projects PTS 30.00.60.10
Human Factors Engineering – Investment justification PTS 30.00.60.12
model
Human Factors Engineering – Design and PTS 30.00.60.18
procurement of skid-packaged units
Standard Form – Human Factors Engineering –Valve PTS 30.00.60.80
criticality ratings
Plant model construction and review PTS 30.10.05.11
Piping – General requirements PTS 31.38.01.11
Instruments for measurement and control PTS 32.31.00.32
Steel structures PTS 34.28.00.31
AMERICAN STANDARDS
Applications Manual for the Revised NIOSH Lifting NIOSH 94-110
Equation
Issued by:
NIOSH (National Institute for Occupational Health and Safety)
395 E Street, S.W.
Suite 9200
Patriots Plaza Building
Washington, DC 20201, USA
http://www.cdc.gov/niosh/
 PTS 30.00.60.13
December 2012
Page 13

APPENDIX A VALVE CRITICALITY ANALYSIS

Valves shall be categorized during the early DEFINE phase, when the PEFS (P&IDs) first
become available, based on their criticality.
Criteria for categorizing and rating valve criticality are provided below. The associated HFE
design criteria are presented in Appendix B. The exact valve classification rating criteria to
be adopted for any project, and the associated rules for HFE design and layout, shall be
reviewed and agreed upon prior to starting the analysis.

A.1 VALVE CRITICALITY RATING

Valves shall be rated by criticality to help ensure that critical valves are located so that they
can be rapidly and effectively identified and operated. The following three categories shall
be used:
• Category 1: Valves critical for safety or operations, valves that are used frequently
(more than once every 6 months) for routine operation and maintenance,
or particularly large valves.
• Category 2: Valves not critical for operations and operated infrequently (less than once
per 6 months) for non-routine operation and maintenance.
• Category 3: Valves not critical for operations or routine maintenance and infrequently
used. Includes valves used exclusively for commissioning, start-up,
shutdown, or rarely performed maintenance tasks.
A.1.1 Category 1 (C-1) Valves
Category 1 (C-1) valves include those essential to normal or emergency operations where
rapid and unencumbered access is essential. The height and reach distances shall conform
to the “Preferred” location as outlined in (B.3) of Appendix B.
Permanent accessibility shall be provided at deck or ground level or via a permanent
standing elevated surface. If such access at ground or deck level is not practical, access by
stairs to the elevated platform is acceptable.
A.1.1.1 Category 1 (C-1) Criteria
These are valves that meet any or all of the following criteria:
• Valves essential to the installation/facility’s operation;
• Valves essential to the installation/facility for safeguarding or safety of personnel;
• Valves with high failure rates and which require rapid corrective action;
• Valves where consequence of failure to obtain quick access would be serious (e.g.
process shutdown and/or damage to facilities or personnel);
• Valves for which the expected operation and/or maintenance is more frequent than
once every 6 months.
A.1.2 Category 2 (C-2) Valves
Category 2 (C-2) valves are those that are not critical for normal or emergency operations
but are used during routine maintenance activities. Height and reach distance of these
valves should preferably be the same as for Category 1 valves i.e., “Preferred” location as
outlined in (B.3) of Appendix B. Category 2 valves may be located within the “acceptable
area” as outlined in (B.3) of Appendix B, depending on their size and the force needed to
operate them.
Where ground level access, or where deck level access by stairs, is not justifiable, a
vertical fixed ladder plus a small standing surface shall be provided for valve operation. The
use of auxiliary equipment to gain access (e.g. mobile platforms, man lift, or scaffolding) for
maintenance purposes may be acceptable as long as it is indicated and allowed for in the
 PTS 30.00.60.13
December 2012
Page 14

design by preserving sufficient space and access for personnel, tools, parts, and
equipment.
A.1.2.1 Category 2 Criteria
These are valves that meet any or all of the following criteria:
• Valves associated with equipment for which rapid intervention is unlikely to be needed;
• Valves with a low operating frequency (i.e. only every 6 months or longer).
A.1.3 Category 3 (C-3) Valves
Category 3 valves are normally non-operating valves that are used in particular
circumstances on an infrequent or rare basis (e.g. hot tap valves, hydrostatic test vent, high
point vent or low point drain valves located in pipe rack).
A.1.3.1 Category 3 Criteria
Permanent accessibility to these valves is desirable but not essential. No specific location
requirements are imposed.
The use of auxiliary equipment to gain access (e.g. mobile platforms, personnel lift, and/or
scaffolding) to these valves shall be indicated and allowed for in the design.
Portable ladders should not be used for accessing valves. Any proposed exception(s) to
this shall be subject to specific review and approval.
Height and reach distances to these valves when operated from auxiliary equipment shall
conform to the “Preferred” location as outlined in (B.3) of Appendix B.

A.2 VALVE CRITICALITY RATING TABLES

To facilitate the valve criticality rating process, two examples of valve listings and criticality
ratings are provided. Table A.1 shows the parameters to be considered when rating valve
criticalities and shows a few examples of assigned ratings. PTS 30.00.60.80 provides a
complete listing for the valves considered so far and will probably be updated with more
valve types when further experience has been gained.
Individual projects may also have to apply some “cultural calibration” for a specific user
population or geographical region or adjust the information in PTS 30.00.60.80 for a
specific project or installation/facility.
When utilizing PTS 30.00.60.80 the VCA session shall determine whether all the
appropriate valve types depicted in the PEFS (P&IDs) are listed and add/delete some if
necessary rating the valve criticality of each valve type.
Once agreement is reached, the criticality category (C-1, C-2 or C-3) shall be recorded and
the associated access and location requirements for each valve type shall be included in
the BDEP/Project Specification. Criticality ratings of valves shall be included on PEFS
(P&IDs), and if a 3D CAD model is being used for design, Category-1 valves shall be coded
therein (e.g. by colour coding 3D shapes).
 PTS 30.00.60.13
December 2012
Page 15

Table A.1 Examples of valve criticality analysis and ratings

Essential High Serious Frequent
Criticality
No. Valve type Process Safe- likelihood consequence operation or
rating
Control guarding of failure of failure maintenance

1. Valves associated with columns/vessels

1.1 Manual In/out isolation valves - - - - - C-2

1.2 Open vent valve (high point vents) - - - - - C-2

1.3 Open drain/utility connection valve (low point) - - - - - C-2

1.4 Closed drain valve - - - - - C-2

1.4 Bypass on isolation valve - - - - - C-2
1.5 Skimming valves (interface bleed valve) Yes - - - Yes C-1
2 Valves associated with tanks
2.1 Manual In/out isolation valves - - - - Yes C-1
2.2 Bottom open drain valve - - - - Yes C-1
2.3 Pressure vacuum valves - - - - Yes C-1
Potable or de-mineralized water connection to
2.4 - - - - - C-2
inlet/outlet line
3 Valves associated with exchangers
3.1 Manual In/out isolation valves - - - - - C-2
etc., etc., etc., etc., etc.,
etc., etc., etc., etc., etc.,

See PTS 30.00.60.80 for a complete listing

 PTS 30.00.60.13
December 2012
Page 16

APPENDIX B HFE DESIGN REQUIREMENTS FOR THE SELECTION, LOCATION AND

ORIENTATION OF VALVE OPERATORS/ACTUATORS

B.1 INTRODUCTION
This attachment provides Human Factors Engineering (HFE) design requirements and
recommendations for the selection of valve operators/actuators and the location and
orientation of valves so that they are easy and safe to operate and maintain.

B.2 VALVE OPERATOR/ACTUATOR

B.2.1 Maximum cracking force
The maximum force required to initially crack open a valve with a handwheel or lever of
more than 125 mm (5 in) in diameter or length shall not exceed 445 N (100 lbf), as
measured on the rim of the handwheel or the end of the lever or wrench. This force limit is
applicable to valves located within the “Preferred” location as depicted in Figures B.1 and
B.2.
For handwheels or levers between 50 mm (2 in) and 125 mm (5 in) in diameter or length
(i.e. intended for one-handed operation) the maximum force shall not exceed 66 N (15 lbf),
as measured on the rim of the handwheel or end of lever or wrench. This force limit is
applicable to valves located within the “Acceptable” and “Preferred” locations as depicted in
Figures B.1 and B.2.
These force limits do not apply to valves located outside the “Preferred” and Acceptable”
regions depicted in Figures B.1 and B.2. Human operators are not able to safely and
reliably exert the specified maximum forces outside those regions. Similarly, these force
limits may not apply to all populations worldwide. They may need to be validated and
amended by a regional HFE Specialist.
Valves should be designed and located so as not to require portable extensions for access
or leverage. Engineered valve wrenches may only be used if the wrench has been
specifically designed for the valve to be operated.
B.2.2 Sustained force
The sustained force to operate a handwheel or lever (i.e. once the valve has been
"cracked") shall not exceed 147 N (33 lbf) for valves with handwheels or levers above
125 mm (5 in) in diameter or length.
B.2.3 Number of rotations
Any valve that requires more than 100 turns to go from fully open to fully closed should be
equipped with motorized (hydraulic, electric or pneumatic) or mobile operators depending
upon the additional considerations in (B.2.4) and (B.2.8).
For applications where a valve may be rotated rapidly through several revolutions, a
spinner handle may be provided. Such handles shall not be used, however, if the projecting
handle is vulnerable to inadvertent movement from a critical wheel setting or if the rapid
rotation creates a safety hazard.
B.2.4 Additional considerations for selecting MOVs or mobile operators/actuators
The following additional factors shall be considered when selecting the type of
operator/actuator:
• In general MOVs or mobile operators/actuators shall be considered for Category 1
(C-1) valves including process control valves (e.g. flow control, emergency isolation
valves, emergency shutdown valves, etc.). They should only be considered for
categories 2 and 3 (C-2 and C-3) in exceptional cases;
• Type of service (crude, steam, water etc.);
• Remoteness of valve (considering travel time);
 PTS 30.00.60.13
December 2012
Page 17

• Available staffing;
• Valve size;
• Access available;
• Operating environment (e.g., hazardous area or during upset condition);
• Extreme climate (heat or cold);
• Frequency of use, i.e. more than once every 6 months;
• Unreliability of infrequently used MOVs (typically MOVs are unreliable if not used on a
regular basis);
• Number of valves to be operated by same operator or group of operators (e.g.,
blending valves, switching reactors etc.), considering workload and potential time
constraints.
B.2.5 Gear operators
If a valve is not an MOV, or is not provided with a mobile operator/actuator or any type of
actuator to assist the operator, and if it requires forces greater than those stated in (B.2.1)
and (B.2.2), then it shall be provided with a gear-operated handwheel.
Table B.1 gives examples of valves that will usually fall in this category.

Table B.1 Examples of valves requiring gear operators (if not MOVs or otherwise
assisted)

ASME Valve Type

Class Gate Globe Ball Butterfly
DN 350 (NPS 14) DN 250 (NPS 10) DN 150 (NPS 6) DN 200 (NPS 8)
150 and larger and larger and larger and larger
DN 300 (NPS 12) DN 200 (NPS 8) DN 100 (NPS 4) DN 200 (NPS 8)
300 and larger and larger and larger and larger
DN 150 (NPS 6) DN 200 (NPS 8) DN 100 (NPS 4)
600 and larger and larger and larger
DN 100 (NPS 4) DN 150 (NPS 6) DN 80 (NPS 3)
900 and larger and larger and larger
DN 100 (NPS 4) DN 80 (NPS 3) DN 80 (NPS 3)
1500 and larger and larger and larger
DN 80 (NPS 3) DN 80 (NPS 3) DN 80 (NPS 3)
2500 and larger and larger and larger

NOTES: 1. The above are examples for guidance purposes. Valve torques can vary for different
manufacturers and shall be checked to ensure appropriate selection of gear operators
based on the maximum and sustained force requirements provided in (B.2.1) and (B.2.2).
2. Some Manufacturers provide gear operators with their standard offer.

B.2.6 Chain operators

Chain-operated valves shall not be used unless approved by the Principal in consultation
with an HFE Specialist.
B.2.7 Remote valve operators
Remote valve operators (RVO) or mechanical extenders, rather than chain operators,
should be used to:
• operate valves that cannot be located within the reach limit distances given in (B.3);
• where permanent access platforms will restrict maintenance access;
 PTS 30.00.60.13
December 2012
Page 18

• in hazardous areas (confined space, below water or where noxious fugitive emissions
may be present).
B.2.8 Mobile operators
The use of appropriate mobile operators (e.g. air drill or nut runner) may be considered for
gear operated valves requiring a large number (> 100) of turns, provided the following
additional requirements are adhered to:
• Mobile operator shall be matched with valve type to ensure no damage to valve
operation;
• Mounting point shall be accessible from a suitable (preferably permanent) standing
surface and have a stop or bracing point to absorb the reaction torque of the mobile
operator;
• To protect the operator of the mobile operator, a torque reaction bar and/or a suitable
mounting bracket shall be used at all times;
• Size, weight and portability of mobile operators shall comply with the appropriate HFE
requirements for lifting and hoisting (consult a regional HFE Specialist for more details).
B.2.9 Manual valves
Manual valves shall be operated by means of a circular handwheel or lever.
Handwheels and levers on all valves shall conform to the operational stereotype of
requiring to be turned in an anticlockwise direction for opening and a clockwise direction for
closing.
Valve handwheels should not be larger than 455 mm (18 in) in diameter. Larger
handwheels may apply more torque but will increase the force application required of the
operator and will also require more space.
Handwheels shall be designed with knurling, indentation, high-friction covering, or a
combination of these to facilitate the operator's grip for applying maximum torque.
Valve lever handles shall be as long as necessary to produce the necessary torque to crack
open and turn the valve but without exceeding the maximum cracking force. Handle lengths
normally range from 355 mm (14 in) to 915 mm (36 in) in length.
Valve lever handles may be of any shape (circular is preferred) but should have a circular
grasping surface for the final 180 mm (7 in) of their length. The grasping surface should be
between 13 mm (0.5 in) and 25 mm (1 in) in diameter and should have a non-slip surface.

B.3 VALVE LOCATION

B.3.1 Access
Valves shall be located so that the operator is provided with a safe and easy access for
operation, inspection, readings and maintenance. Valves shall not be acessed by standing
on, or with the aid of, adjacent pipe-work, insulation, pipe-racks, cable trays, handrails, or
any other equipment or object.
The minimum distance between any obstruction and handwheel/valve stem stipulated in
Figure B.2 is for valve operation only and does not include workspace needed for
maintenance.
Valve stems shall be checked in both their closed and open position when assessing
clearance envelopes for operation and ensuring that stems do not constitute a potential
obstruction hazard to operators (e.g. protruding into an escape route or walkway).
A minimum of 75 mm (3 in) clearance shall be provided between the outside rim of a valve
handwheel or the end of a valve handle and any obstacle located within the field of travel of
the handwheel or handle. For valves installed in Arctic environments, the minimum
clearance provided shall be increased to 125 mm (5 in).
Drain valves shall be located outside vessel skirts.
 PTS 30.00.60.13
December 2012
Page 19

B.3.2 Position indicators

Valves equipped with valve position indicators shall be installed so that the indicator’s
status is directly visible from a normal vantage point (e.g. adjacent to walkway) when
opening or closing the valve. For valves fitted for remote control, an independent indicator
showing whether the valve is open or closed shall be provided on or adjacent to the control
that is visible from the operator’s normal standing position.
B.3.3 Mounting heights
B.3.3.1 Handwheel operated valves
Valve handwheels shall be mounted in the “Preferred” or “Acceptable” vertical and
horizontal locations as shown in Figures B.1 and B.2, depending on valve stem orientation
and maximum force requirements as stated in (B.2.1) and (B.2.2). See notes and
exceptions to these dimensions at the bottom of the figures.

Unacceptable

1300 mm
(51 in)

Preferred

455 mm
(18 in)

Acceptable

150 mm
(6 in)

455 mm Grade/deck
(18 in)
Max. horizontal distance from
obstruction or operator’s front

NOTES: 1. Distances or heights are measured to handwheel centreline. For gear-operated valves with a
handwheel provided with a spinner handle, maximum horizontal distance is measured to the edge
of the handwheel furthest from the operator.
2. Heights are to be to the maximum extension of valve stem for rising stem valves.
3. These dimensions are appropriate male and female personnel worldwide from 5th to 95th
percentile, except that the top limit for the “Preferred” choice location should be reduced by 100
mm (4 in) to accommodate male and female populations in regions such as West Africa,
Southeast Asia, Southern China, parts of Latin America, India and Japan.
4. For valves located below 455 mm (18 in), sufficient clearance of at least 1300 mm (51 in) should
be provided behind the operator to accommodate a bending or kneeling posture.

Figure B.1 Mounting heights for hand-wheel operated valves with vertical stems
 PTS 30.00.60.13
December 2012
Page 20

Min. 610 mm (24 in) between

any obstruction
and hand wheel/valve stem

Unacceptable

1830 mm
(72 in)

Preferred

610 mm
(24 in)

Acceptable

230 mm
(9 in)

Grade/deck
455 mm
(18 in) Max. horizontal distance from obstruction,
or operator’s front

NOTES: 1. Distances or heights are measured to handwheel centreline. For gear-operated valves with a
handwheel provided with a spinner handle, maximum horizontal distance is measured to the edge
of the handwheel furthest from the operator.
2. These dimensions are appropriate for personnel worldwide, from the 5th percentile of the female
population to the 95th percentile of the male population, except that the top limit should be set at
1755 mm (69 in) for 5th percentile males and 66 in (1675 mm) for 5th percentile females in regions
such as West Africa, Southeast Asia, Southern China, parts of Latin America, India and Japan.
3. For valves located below 455 mm (18 in), sufficient clearance of at least 1300 mm (51 in) should
be provided behind the operator to accommodate a bending or kneeling posture.

Figure B.2 Mounting heights for handwheel operated valves with horizontal stems
B.3.3.2 Lever operated valves
Valve levers shall be mounted in the locations as shown in Figures B.3 and B.4, depending
on valve stem orientation and maximum force requirements (B.2.1). No valve handles shall
protrude into walkways or work areas when the valve is in the closed position.
 PTS 30.00.60.13
December 2012
Page 21

760 – 1300 mm
(30 – 51 in)

Grade/deck

NOTE: These dimensions are appropriate for personnel worldwide, from the 5th percentile of the female
population to the 95th percentile of the male population, except that the top limit should be reduced to
1145 mm (45 in) to accommodate 5th percentile females in regions such as West Africa, Southeast
Asia, Southern China, parts of Latin America, India and Japan.

Figure B.3 Mounting heights for lever-operated valves with vertical stems

A) Max. height to top of handle

when handle rotates up from the
centreline = 1905 mm (75 in)

A) Max. height to top of handle Above 1300 mm (51 in)

when handle rotates down from the or between
centerline = 1905 mm (75 in) 150 – 760 mm (6 – 30 in)

Grade/deck

NOTE: These dimensions are drawn for North American males, and are therefore appropriate for other
regions such as Northern Europe, Australia, UK, and Central Europe. These dimensions should be
reduced to 1805 mm (71 in) for 5th percentile males in areas such as West Africa, Southeast Asia,
Southern China, parts of Latin America, India and Japan, and 1725 mm (68 in) for 5th percentile
females in West Africa, Southeast Asia, Southern China, parts of Latin America, India and Japan. To
accommodate the same international population of 5th percentile females, horizontal stem valves
should be located at least 1145 mm (45 in) above the standing surface, rather than 1300 mm (51 in)
as shown.

Figure B.4 Mounting heights for lever-operated valves with horizontal stems
Valves oriented with the stem in a horizontal position are preferred when the lever is
located between 150 mm and 760 mm (6 in and 30 in), or more than 1300 mm (51 in)
above the deck as shown in Figure B.4. However, the maximum height above the deck to
the valve tip should not exceed 1905 mm (75 in). The valve handle is not permitted to rotate
down from centreline if there is a walking surface directly underneath.
 PTS 30.00.60.13
December 2012
Page 22

Valves in a vertical section of the pipe e.g., located in a manifold or at battery limit, shall be
oriented with all the stems on the same side as shown in Figures B.5 and B.6, with a
75 mm (3 in) clearance maintained between the lever and any obstruction.

X X X = 75 mm (3 in) minimum

All levers oriented in same

direction when open/closed

Y – see Table B.2

Grade/deck

Figure B.5 Manifold or battery limit valves with 75 mm (3 in) minimum gap between
lever-end and the nearest flange/obstruction

X = 75 mm (3 in) minimum
X X

All levers oriented in same

direction when open/closed

Y – see Table B.2

Grade/deck

Figure B.6 Manifold or battery limit valves with 75 mm (3 in) minimum gap between
front face of lever’s outer surface and nearest flange/obstruction
 PTS 30.00.60.13
December 2012
Page 23

Table B.2 Height of valve lever end above grade/deck

Height (Y) of valve lever end above grade/deck

Preferred 610 mm to 1905 mm (24 in to 75 in)
Acceptable 230 mm to 610 mm (9 in to 24 in)
Unacceptable < 230 mm or > 1905 mm (< 9 in or > 75 in)

B.3.3.3 Valves operated from vertical ladders

Category 1 (C-1) valves shall not be located so that they have to be operated from a ladder
(caged or uncaged)
Other valves should not be located so that they have to be operated from a ladder, but if
this is unavoidable the following requirements shall apply:
• The handwheel or lever shall be located between 150 mm (6 in) and 610 mm (24 in)
from the edge of the ladder stringer in order to open and close the valves, as shown in
Figures B.7 and B.8;
• Valve location, orientation, and actuator type shall be selected to enable opening or
closing with one-hand only.

150 mm 150 mm Vessel

(6 in) min (6 in) min

Vertical Horizontal
stem valve stem valve

LT LG

610 mm 610 mm
(24 in) max (24 in) max

Figure B.7 Required lateral reach distances (minimum and maximum) for level
instruments, gauge nozzles or valves on the side of a vessel;
lever/handle operated
B.3.4 Valve Maintenance Considerations
B.3.4.1 Access
The minimum distance between valve flanges and any obstruction shall be the bolt length
plus 25 mm (1 in) to allow access for hand tools and torquing of bolts.
Where standing room is required for maintenance access to valve flanges, the clearance
between a flange and a wall, structural steel, or guardrail shall not be less than 460 mm
(18 in).
 PTS 30.00.60.13
December 2012
Page 24

150 mm 150 mm Vessel

(6 in) min (6 in) min

Vertical Horizontal
stem valve stem valve

LT LG

610 mm 610 mm
(24 in) max (24 in) max

Figure B.8 Required lateral reach distances (minimum and maximum) for level
instruments, gauge nozzles or valves on the side of a vessel; hand-
wheel operated.
B.3.4.2 Valve mass and lifting aids
Valves with a mass less than 23 kg (50 lb) shall be located so that they can be lifted by one
person without risking injury through poor lifting posture. Valves with a mass less than
45.5 kg (100 lb) shall be located so that they can be lifted by two persons, provided the
valve can be lifted without having to reach over or around items between the persons and
the valve.
NOTE: The 23 kg (50 lb) limit is the lifting equation load constant in NIOSH 94-110. The recommended mass
limit assumes a single lift and optimum lift-height, lift-distance and body position. For any repetitive
type lifting or non-optimal body positioning, the lift height or distance, and other relevant handling
factors, a regional HFE Specialist shall be consulted.

For all valves in excess of the above weight limits and lifting heights that must be lifted for
repair, replacement or maintenance, permanent or portable assisted lifting devices (e.g.
‘chain-falls’, ‘lever chain puller/hoist’) shall be provided to aid the lifting or moving. If such
devices are provided, space for them and the personnel who use and manoevre them shall
be provided.
Assisted lifting devices provided to assist in lifting or moving equipment should be able to
be located (e.g. by means of pad eyes or beam clamps) directly over the item to be lifted so
the lift is vertical to prevent swinging loads when the items are raised or lowered. Two lifting
aids may be used simultaneously, one on each side of the valve, if a vertical lift is not
feasible.
Hoisting areas should be free of obstacles such as cable trays, HVAC ducting, structural
components, piping, and other equipment within a radius of at least 305 mm (12 in) at the
point of hookup to the device.
There shall be sufficient clearance above each valve to attach the lifting device and pull the
valve or valve operating mechanism, or to complete all maintenance tasks in place without
removing the valve.

Last page of this PTS