Governing document Classification: Internal

Valve Actuators

Project development (PD)

Technical and professional requirement, TR0038, Final Ver. 3, valid from 2012-10-01

Owner: Leader TNE PRT MET PLAH

Validity area: Corporate technical requirements/On- and offshore

Governing document: Valve Actuators Classification: Internal

1 Objective, target group and provision ............................................................................................................... 4

1.1 Objective .................................................................................................................................................... 4
1.2 Target group .............................................................................................................................................. 4
1.3 Provision .................................................................................................................................................... 4
2 General requirements .......................................................................................................................................... 4
2.1 General ...................................................................................................................................................... 4
2.2 Environmental data .................................................................................................................................... 4
3 Functional requirements ..................................................................................................................................... 5
3.1 General ...................................................................................................................................................... 5
3.2 Valve operating speed ............................................................................................................................... 5
3.3 Actuator selection and sizing ..................................................................................................................... 5
3.4 Sizing of accumulators............................................................................................................................... 7
4 Material requirements .......................................................................................................................................... 8
4.1 General ...................................................................................................................................................... 8
4.2 Manufacturing records and traceability ..................................................................................................... 8
4.3 Actuators .................................................................................................................................................... 9
4.4 Pressure vessels ..................................................................................................................................... 10
4.5 Tagged instruments ................................................................................................................................. 10
4.6 Instrument commodity items.................................................................................................................... 10
4.7 Framework, cabinets and junction boxes ................................................................................................ 10
4.8 Static environmental seals ....................................................................................................................... 10
5 Instrumentation................................................................................................................................................... 11
5.1 General .................................................................................................................................................... 11
5.2 Supply utilities .......................................................................................................................................... 11
5.3 Signal types ............................................................................................................................................. 11
5.4 Air filter regulator ..................................................................................................................................... 12
5.5 Limit switches........................................................................................................................................... 12
5.6 Mechanical details and workmanship...................................................................................................... 12
5.7 Actuator control circuits ........................................................................................................................... 14
6 Electrical operation ............................................................................................................................................ 17
6.1 General .................................................................................................................................................... 17
6.2 Design ...................................................................................................................................................... 17
6.3 Electric motors ......................................................................................................................................... 17
6.4 Torque and turns limitation ...................................................................................................................... 18
6.5 Control facilities........................................................................................................................................ 18
6.6 Monitoring facilities .................................................................................................................................. 18
6.7 Hand wheels ............................................................................................................................................ 18
7 Mechanical requirements .................................................................................................................................. 19
7.1 General .................................................................................................................................................... 19
7.2 Design of pressure retaining equipment.................................................................................................. 20
7.3 Springs ..................................................................................................................................................... 21
7.4 Adaptor stool ............................................................................................................................................ 21
7.5 Fire protection .......................................................................................................................................... 21
7.6 Mechanical valve locking ......................................................................................................................... 22
7.7 Lifting lugs and eyebolts .......................................................................................................................... 22
8 Marking ................................................................................................................................................................ 23
8.1 Identification plates .................................................................................................................................. 23
8.2 Tags and labels........................................................................................................................................ 23
9 Testing and cleaning requirements.................................................................................................................. 25
9.1 Inspections at supplier works .................................................................................................................. 25
9.2 General testing requirements .................................................................................................................. 25
9.3 Functional tests ........................................................................................................................................ 25
9.4 Factory Acceptance Tests (FAT). ............................................................................................................ 27
9.5 Cleaning and flushing .............................................................................................................................. 28
10 Surface protection .............................................................................................................................................. 30
10.1 General .................................................................................................................................................... 30

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10.2 Colours ..................................................................................................................................................... 30

11 Documentation including Life Cycle Information (LCI) ................................................................................. 31
11.1 General .................................................................................................................................................... 31
11.2 General requirements for all procedures ................................................................................................. 31
11.3 Bid documentation ................................................................................................................................... 31
11.4 Supplier Information Requirement List (SIRL) ........................................................................................ 32
11.5 Mechanical Completion / Commissioning Dossier .................................................................................. 35
11.6 Safety Integrity and Reliability Requirements ......................................................................................... 35
12 Additional requirements .................................................................................................................................... 36
12.2 Changes from previous version ............................................................................................................... 38
12.3 References ............................................................................................................................................... 39
App A Control circuits (normative) .............................................................................................................................. 41
App B Optional control circuits (informative) ............................................................................................................. 42
App C Applicable for valves supplied to the European Community (normative for applicable area) ................. 43
C.1 Design of Equipment ............................................................................................................................... 43
C.2 Marking .................................................................................................................................................... 43
App D Applicable for valves supplied to Norway or Norwegian part of continental shelf (normative for
applicable area)................................................................................................................................................... 44
D.1 Design of equipment ................................................................................................................................ 44
App E Applicable for valves supplied to Snorre A..................................................................................................... 45
E.1 Environmental data .................................................................................................................................. 45
E.2 Instrumentation ........................................................................................................................................ 45
E.3 Actuator selection and sizing ................................................................................................................... 46
E.4 Documentation requirements .................................................................................................................. 46
E.5 Nominated manufacturers ....................................................................................................................... 46
E.6 References ............................................................................................................................................... 47
E.7 Typical control circuits ............................................................................................................................. 47
App F Applicable for valves supplied to Gullfaks...................................................................................................... 48
F.1 Environmental data .................................................................................................................................. 48
F.2 Instrumentation ........................................................................................................................................ 48
F.3 Mechanical requirements ........................................................................................................................ 49

Project development (PD), Technical and professional requirement, TR0038, Final Ver. 3, valid
from 2012-10-01
Page 3 of 49
Validity area: Corporate technical requirements/On- and offshore
Governing document: Valve Actuators Classification: Internal

1 Objective, target group and provision

1.1 Objective
The objective of this document is to define the technical requirements for actuators, control circuits
and accumulators for remotely operated on/off valves.

1.2 Target group

The main target group for this document is actuator and valve suppliers; however personnel and
contractors involved in project development of new onshore and offshore facilities or modification of
existing facilities should also be familiar with the requirements in this document.

1.3 Provision
This document is provided for in TR3010 Mechanical, Technical Requirements and Standards.

2 General requirements

2.1 General
The technical requirements contained in this specification are in addition to those defined by
Purchaser in TR2000 “Piping and Valve Material Specification” and other referred standards and
specifications.

This specification excludes requirements for the following actuator locations:

x High Integrity Pressure Protection Systems (HIPPS) (TR1956).
x Surface Wellhead and Christmas Tree System, APOS DW-T10-01 (TR1830).
x Subsea X-mas Tree and Completion/Workover Riser Systems (TR0034).
x Subsea Production System valves and large HP valves in pipeline transportation systems
(TR1236).
x Control & Choke Valves (TR2212).

The minimum requirements herein are still applicable for the above excluded systems if the actuated
valve is given an additional safety function to its original function in the process plant.

Selection of actuator type is Purchaser responsibility and is described in TR3032.

Any information applicable for purchaser’s consideration to select mode of actuation, space
requirements (maintenance, material handling etc.) and the effect on weight and equipment stability
shall be highlighted by supplier.

2.2 Environmental data

The design temperature range shall be based on the ambient temperature range defined in the design
basis for the applicable project/installation/plant. The atmosphere shall be considered humid and
corrosive.

Unless otherwise specified, Supplier will be responsible for supplying equipment suitable for the
above conditions.

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3 Functional requirements

3.1 General
The PO shall define the selected valve design and details, as well as the functional requirements by
pre-selecting the control circuit function and thereby also define the selected actuator type
(single/double acting, hydraulic/pneumatic/electric).

The valve supplier shall have full responsibility for the design, construction and functionality of the
valve-actuator assembly including all accessories, local control circuits and accumulators. The valve
supplier shall in close liaison with the actuator supplier calculate and select the most suitable actuator
and control circuit capacity that will satisfy the requirements set forth in the PO’s.

Actuator failure mode shall ensure the correct valve position required for the safe operating condition.

Service life shall be minimum 20 years unless otherwise specified.

3.2 Valve operating speed

All actuated valves shall be equipped with adjustable speed setting components. For detailed
requirements reference is made to 5.7 Actuator Control Circuits.

Typical response times that shall be complied with unless other requirements are specified:
x Time from activation to start execution, e.g. de-energized solenoid valve, shall be less than 2
seconds.
x ESD valve travel time (in service) at minimum operating hydraulic/pneumatic supply pressure
shall not exceed 2 sec/inch (valve size), or maximum 45 seconds to reach safe state. For
valves 8 inch or less, a typical travel time may be set to 15 seconds. Travelling speed when
travelling from the predefined safe position shall be agreed between buyer and supplier.

For valves that by size or design fail to meet the required speed, the Supplier shall notify the
Purchaser about the limitations and seek alternative solutions together with the Purchaser.

The actuator shall be equipped with a “maximum speed device” fitted on or in the actuator with
sufficient mechanical strength to withstand breakage. Unless otherwise specified, the maximum
speed shall be limited to 0.5 sec/inch (valve size) in case of a physical breakage of tubing connected
to the actuator. The “maximum speed device” shall not influence the valve in reaching its predefined
safe position on demand.

3.3 Actuator selection and sizing

3.3.1 General
The dimensioning of the actuator shall be valve supplier’s responsibility in close cooperation with the
actuator supplier. A description of the required service application will be submitted in a Process Data
Sheet (PDS). In addition, an Instrument Data Sheet (IDS) and a Valve Data Sheet (VDS) with referred
attachments will be presented in the PO.

Typical information provided by Purchaser will be:

x Type and size of valve

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x Type of actuator
x Line pressure
x Maximum service media differential pressure
x Operating temperature
x Type of fluid in the line
x Ambient temperature
x Pneumatic/hydraulic/electric power supply
x Opening/closing times

In addition the valve supplier shall include (obtained from actuator supplier if relevant) experience
data such as:
x Valve stem size and packing design/compression
x Valve wear and degradation
x Relaxation of springs
x Increase of valve torque and thrust when the valve is stationary in one position during a
prolonged period of time

3.3.2 Actuator sizing

Actuator selection and sizing shall normally be based on:
x Maximum service media system operating conditions. When using differential pressure
situations due attention shall be given to pressure combinations, such as up-stream, down-
stream, pressure in valve cavity, static pressure, effects from media flow, etc. (special
attention shall be given to valves with double piston effect seat design where cavity pressure
can reach 133% of DP).
x Nominal hydraulic or pneumatic operating pressure shall be as defined in 5.2.
x The drive chain shall be able to tolerate maximum hydraulic or pneumatic operating pressure
as defined in 5.2. Where the actuator capacity exceeds 90% of the yielding capacity of the
stem or any other part in the drive chain, the valve supplier shall seek clarification. If valve
stem material is modified from material specified on the VDS, this shall be approved by
Company in a Concession Request (CR).

For slab gate valves of the reverse acting type, the contributing closing force from the media pressure
shall not be accounted for when dimensioning actuators. Any deviation to this requirement shall be
approved by Company in a CR.

This capacity shall be available in a dimensioning fire situation and as a minimum with a spring
temperature up to 100 0C.

Actuators shall be designed to the maximum supply pressure. If circumstances favour otherwise, the
use of a pressure reducing feature in the supply pressure lines in order to reduce actuator output
capacity can be proposed to Company through a Concession Request (CR). If approved, the
pressure reduction feature shall be in accordance with ISO 12490 section 9.2.

Purchaser shall be informed about any limitations on the equipment that may be relevant for each
application. This can typically be an order with a remotely mounted control panel/cabinet with no
reference to the distance between control panel and actuator/valve. In such case it shall be the
Suppliers responsibility to request additional information from Purchaser to ensure that the required
capacity will be met. An average tube run distance of 15 metres shall be assumed. For dimensioning

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of hydraulic oil systems, a back-pressure of ten (10) bar g in the return line shall be used unless
otherwise agreed between Purchaser and Supplier.

3.3.3 Safety factors

In general actuators for ESV, BDV and XV valves shall be dimensioned with a minimum safety factor
of 2.0. It is permitted that the safety factor for the travel to the non-safe position may be reduced to a
minimum of 1.5 (e.g. for a spring/piston operated valve where the fail-safe travel is operated by the
spring, the minimum safety factor for the piston displacement/spring charging shall be 1.5, whilst the
spring movement shall maintain a minimum safety factor of 2.0).

All other valve actuators shall use a minimum safety factor of 1.5.

Safety factors shall be calculated using the nominal supply pressure/voltage values as provided by
the Purchaser. The safety factor shall also apply for springs through the complete valve stroke.

Purchaser may, for individual valves, require a different safety factor, as well as the Supplier might
recommend a different value based on experience at the given service conditions. This shall be
approved by Company in a CR.

3.4 Sizing of accumulators

"Fail open" or "fail close" mode of spring-less double-acting piston actuators shall be accomplished by
the use of accumulators and switching valves. The accumulator capacity shall normally be sized for at
least three (3) strokes of valve operations within full operating temperature range (including minimum
temperature) and starting at nominal operating pressure as defined in 5.2.

One stroke is the movement of the valve from open position to closed position or from closed to open.

At the end of the third stroke, the remaining accumulator pressure shall not be less than the minimum
operation pressure as defined in 5.2.

For non-safety critical valves larger than 20", the stored power capacity may be reduced to 1.5
strokes. If this is selected, the accumulator gas expansions temperature drop has to be taken into
consideration. Normally the pre-charge gas isothermic behaviour, at the lowest ambient temperature,
has to be used. If the calculation shows that, after one actuator stroke, there is not sufficient power
immediately available for another half stroke, additional gas volume has to be included. The
requirement for the available 1.5 stroke power is that after a theoretical 150 % travel, with the actual
accumulator piston, the minimum pressure for valve closure is still available (ref. isothermal
expansion).

‘Non-safety critical valves’ will be defined in the PO based on an evaluation where current authority
regulations are taken into consideration.

Air reservoirs shall be able to be charged to the maximum air supply pressure requiring a leak free
non-return valve.

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4 Material requirements

4.1 General
Generally, all equipment must withstand humid and corrosive atmosphere. Special conditions like e.g.
severe condensation, sea water, fire water spray, steam and AFFF may be specified in PO.

Components in plastic (non-metallic) materials shall not be used (except solenoid coil and limit switch
housings).

General accessories such as nuts, bolts, indicator pins, etc., assembled in direct contact with
stainless steel equipment, shall be in AISI 316 SS.

All carbon steel components and surfaces exposed to the atmosphere shall be coated to the referred
surface treatment standard in this document.

For electric actuators, alternative use of aluminium material grades may be accepted if the aluminium
grade(s) is documented as a corrosion resistant material grade in marine and saline atmosphere. If
any aluminium grade is used, a proper specification shall be established as described in section 11.4.

All welding shall be continuous and welding of stressed components shall be full penetration welds.
When welding is applied onto components specified as 316 SS material, the material grade shall be
AISI 316L.

4.2 Manufacturing records and traceability

The Manufacturing Records represents the Supplier’s computer system / reference to calculations
together with the necessary drawings, manufacturing, testing and inspection procedures,
certifications, and non-conformance reports required to demonstrate that the product (actuator /
accumulators / control circuit as applicable) is in compliance with all specified requirements.

The Manufacturing Records shall include: material certificates, relevant welding procedure
specification and qualification, repair weld maps, NDE reports together with lists of welder and NDE
operator qualifications and NDE procedures. Relevant fabrication drawings and sketches must be
included to facilitate the understanding of welding, heat treatment and NDE records. There shall be
traceability from the applicable item to all documents in the Manufacturing Records.

Manufacturing Records shall be stored for at least 10 years following the commencement of the
guarantee period. Supplier shall be able to provide information in the Manufacturing Records, as
defined above, when required by Company. On written request, Manufacturing Records
documentation shall be provided within 15 working days.

Supplier is obliged to:

x offer the Manufacturing Record documentation free of charge to Purchaser
x submit the Manufacturing Record documentation to Purchaser if for any reason the Supplier
ceases to operate
x notify Company prior to destruction of any manufacturing records

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4.3 Actuators
Table 1 – Material requirements for actuators

Description of actuator part Material selection/design requirements

Valve actuator cylinder: Nodular cast iron/Carbon steel/AISI 316 SS
Actuator yoke housing: Nodular cast iron/Carbon steel/AISI 316 SS
Actuator end covers: Nodular cast iron/Carbon steel/AISI 316 SS
Act. yoke fork, rack & pinion: Nodular cast iron/Carbon steel/AISI 316 SS
Actuator spring housing: Nodular cast iron/Carbon steel/AISI 316 SS
Piston rods and shafts exposed to AISI 316 SS, Duplex SS or 17-4 PH. Other stainless
atmosphere: steel materials to be approved by Company
Tie rods, nuts and bolts dia. ”10 mm, AISI 316 SS, Duplex SS or in material with equal or
stroke adjustment components and better corrosion resistance
washers:
External nuts and bolts dia. larger than 10 Hot-dipped galvanised CS to ASTM A153, or AISI 316
mm: SS, Duplex SS or in a material with equal or better
corrosion resistance
Adapter stool (connector between actuator AISI 316 SS, Duplex SS or in material with equal or
and valve): better corrosion resistance.
Adapter stool in carbon steel are acceptable with the
following requirements:
o The adaptor stool shall be galvanized and painted.
o Machining is acceptable on flange faces towards
actuator and valve after galvanizing.
o Machined surfaces shall as a minimum be painted.
o It is acceptable to drill and thread holes after
galvanizing.
o The flange faces between actuator and valve shall
be preserved with rust and corrosion preventive
product like e.g. a black bituminous spray during
assembly to preserve potential paint damages
coming from assembling or operational movement
between the parts
Coupling (connection between valve and AISI 316 SS, Duplex SS or 17-4 PH. Other stainless
actuator shafts): steel materials to be approved by Company by a CR
Actuator/valve connection bolts: Carbon steel according to ASTM A193 B7/2H, hot dip
galvanised to ASTM A153
Brackets for limit switches, junction boxes AISI 316 SS
and other ancillaries, support structures
between actuator and valve:
Grease nipples: AISI 316 SS
Hand wheel for manual override Hand wheels and handles shall be in stainless steel
(minimum SS304/316) or hot dip galvanized carbon
steel according to ISO 1461. Hand wheels or handles
galvanized according to ISO 1461 shall be painted in
accordance with requirements in section 10.2.1.
Hand wheels made from machine pressed tin is not
permitted.
Note : Duplex SS means UNS S31803/UNS S32205 or equivalent grades.

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4.4 Pressure vessels

Accumulators: AISI 316 SS
Nitrogen bottles: According to BS 5045, Part 7
Air reservoirs: AISI 316 SS

4.5 Tagged instruments

Solenoid/control valves and fittings shall be purchased as specified by project/installation/plant
documentation.

Table 2 – Material requirements for tagged instruments

Description of tagged instrument part Material selection/design requirements

Hydraulic solenoid/control valve body & coil housing: AISI 316 SS
Pneumatic solenoid/control valve housing: AISI 316 SS
Pneumatic solenoid/control valve solenoid coils: Glass-fibre reinforced plastic housing/
AISI 316 SS
Limit switches: AISI 316 SS
Accumulator piston position indicator (if mechanical): AISI 316 SS
Valve position indicator: AISI 316 SS/plastic

4.6 Instrument commodity items

Air filter regulators: AISI 316 SS
Instrument fittings: AISI 316 SS
Instrument manifolds: AISI 316 SS
Instrument valves: AISI 316 SS
Rupture discs: AISI 316 SS
Small relief valves: AISI 316 SS
Tubing: 6Mo or 25% Cr Duplex
Pressure indicators: AISI 316 SS
Booster: AISI 316 SS

For temperatures above + 60 deg. C and in external and saliferous atmospheres 6Mo, 25% Cr Duplex
or Hastelloy C-276 shall be specified for fittings and commodity items.

For temperatures below +60 deg. C, Purchaser may request 316 SS tubing for use in indoor and dry
atmospheres, or external non-saliferous atmospheres.

4.7 Framework, cabinets and junction boxes

Framework for control circuits, Control circuit plate (min. 3 mm thickness), Protection shield along
control circuit top, Cabinets for control circuits and Junction boxes: AISI 316L SS.

4.8 Static environmental seals

Soft seal material shall be suitable for the specified service conditions. O-rings shall be according to
MDS PG301.

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5 Instrumentation

5.1 General
All equipment shall comply with the requirements of the specific hazardous area in which they will be
installed.

The equipment shall be certified for Zone 1, Gas Group IIA, and temperature class T3 as a minimum
unless specified otherwise by Purchaser in PO.

Preferred protection methods are Ex (e), Ex (i), and Ex (m) in accordance with IEC 60079.
For field instruments like limit switches Ex (i) shall be used in maximum extent possible.
For junction boxes and glands Ex (e) shall be used in maximum extent possible.
For solenoid valves Ex (m) shall be used in maximum extent possible.

The minimum degree of protection provided by enclosures shall be IP 56 in accordance with IEC
60529.

Pneumatic/control valve solenoid coils shall be with completely encapsulated coil, screw terminals
within terminal box and cable connection to be ISO metric, pitch 1.5 mm.

5.2 Supply utilities

Air supply
Unless otherwise specified by Purchaser the on/off valve application shall be designed and sized for
the following:
x Minimum operating pressure: 5,5 bar g
x Nominal operating pressure: 7 bar g
x Maximum operating pressure: 12 bar g

Hydraulic supply
Unless otherwise specified by Purchaser, the hydraulic actuators, control systems and accumulators
shall be designed and sized for:
x Minimum operating pressure: 160 bar g
x Nominal operating pressure: 200 bar g
x Maximum operating pressure: 210 bar g

Electrical supply
Purchaser shall specify the type of power supply for field instruments and electric actuators, including
voltage, AC/DC, phase and frequency.

Voltage tolerances: +/- 10%

Frequency tolerances: +/- 5%

5.3 Signal types

The following signal types shall be the preferred choice for electrically hardwired field devices:

Table 3 – Signal types

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Signal Type
Analogue input 4 – 20 mA with HART protocol
Analogue output 4 – 20 mA with HART protocol
Digital input Potential free contact
Proximity switches with NAMUR interface according to IEC60947-5-6
Digital output 24 VDC

5.4 Air filter regulator

Air filter regulators shall be provided with integral relief valve and micron filter. If regulator supply
pressure is lost, downstream air pressure shall be relieved.

5.5 Limit switches

Limit switches shall for European locations be of inductive type with NAMUR interface according to
IEC60947-5-6, for other locations in accordance with PO requirements.

When limit switches are specified they shall normally be fitted inside a combined switch
house/junction box, complete with terminals. This should be mounted to the actuator or valve body for
termination of flying leads according to section 5.6.5. The limit switches shall be installed on rigid AISI
316 SS steel fixing plates or brackets and shall be easily adjustable.

Flying leads from limit switch to junction box shall be physically protected by the design. If no other
options are possible 316 SST tubing should be used.

The limit switches shall be activated by the movement of the valve shaft or stem and shall switch at
less than 5% of the movement of the respective limit.

Limit switches should have integral LED indication.

5.6 Mechanical details and workmanship

5.6.1 Design considerations

The technical design and arrangement of all equipment shall carefully consider the following:
x Wear resistance
x Protection against damage
x Protection against vibration
x Operability and serviceability

5.6.2 Work with tubing and compression fittings

5.6.2.1 General
The installation shall be done by skilled personnel who have participated in the applicable fitting
manufacturer's training course or general tubing and compression fittings training course before they

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are allowed to work with tubing and compression fittings. A successful performance of the course
shall be documented by a qualification certificate, which shall be accessible on request.

The make and type of fittings will be specified in the PO.

Instrument valves shall be mounted in accordance with supplier recommendations where mounting
position and contamination can affect the valve function. Instrument ball valves shall only be used for
on/off operation.

All instrument tubing shall be in metric size. The Supplier shall use preferred standard size but shall
evaluate and advise if other outside diameters are required for any reason. The following instrument
tubing outside diameters are preferred:

x 10 mm, 16 mm, 20 mm and 25 mm

Fire resistant, braided flexible hose connection between the tube and the actuator final fitting may be
considered when there is risk of high vibration, and shall be subject to company approval.

Any loose items shall be put in a small plastic bag and fastened with ”strips” onto the equipment close
to the applicable mounting position.

5.6.2.2 Hydraulic & Nitrogen services

For hydraulic applications, and N2 services for hydraulics, compression tube fittings shall be used.

Threaded end fittings (without adapters) shall be to ISO 1179-2 with BSPP threads to ISO 228-1,
sealing surface to DIN 3852, form A, utilising a bonded seal packing in 316 SS/PTFE or 316 SS/NBR
(Explosive decompression proof if used in Nitrogen service).

Thread sizes shall be 1/4”, 3/8”, ½”, ¾” or 1” unless there are specific requirements in PO’s.

All interface tube fittings shall be included in the equipment units and shall be plugged with suitable
AISI 316 SS caps prior to shipment.

All parts of the assembly shall be thoroughly cleaned by mechanical means before any washing or
flushing is attempted. All tube ends, ports in solenoids etc. shall be de-burred on the outside and
inside and blown through with air before assembly.

NPT threaded connections may be used when specifically requested by Purchaser. This may be
inside plants where the same types of connections have been previously used.

5.6.2.3 Pneumatic service

For pneumatic systems NPT threaded connections (ASME B1.20.1 or B1.20.2M) shall be used.

All interface tube fittings shall be included in the equipment units and shall be plugged with suitable
AISI 316 SS caps prior to shipment.

On NPT-threaded compression fitting, the sealing compound for process services and instrument air
services shall be recommended by purchaser. Teflon tape will not be accepted.

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5.6.3 Actuator- valve Interface

The actuator interface to the valves shall preferably be standardised accepting different valve sizes
according to ISO 5210 or ISO 5211. Actuators, adapters, connections and valves must be sufficiently
strong and rigid to comply with the requirements in section 7.

Rotary type actuators shall use dowel pins or key for securing fixed position between actuator and
valve.

5.6.4 Cable installation

Cable installation, termination and earthing shall comply with statutory regulations and applicable
specifications (ref. TR3023 and TR3024).

Purchaser will detail the requirements for cables in the PO.

5.6.5 Junction boxes

Junction boxes shall be complete with terminals suitable for 2.5 mm2 cross section copper
conductors, mounting rails, endplates etc. and with suitable earth continuity plate for the cable glands
and thus the cable armouring/lead sheathing where applicable.

Purchaser will advise the make of cable glands in the PO.

All cable entries shall preferably be in the bottom of the junction box. If this is not practical the sides
can be used, if approved by COMPANY. No cable entries are permitted at the top of the junction box.
Unused penetrations shall be carefully plugged before shipment.

Intrinsically safe (IS) circuits shall be coloured light blue and have Ex (i) type terminals. Ex (e) type
terminals shall be used for all other circuits. All terminals shall accept conductors with 2.5 mm2 cross
section and be made using crimping pins.

Threads for electrical glands shall be ISO metric, pitch 1.5 mm. Heat shrinking sleeves covering
glands shall not be used. Glands of GRP make shall not be used.

5.7 Actuator control circuits

5.7.1 General
The actuator control circuit represents the interface between different control/safety computer
systems and the on/off valve. Schematic control circuits for hydraulic/pneumatic actuated valves are
shown in Appendix A and Appendix B.
Control panels for the different circuit types shall be standardised in size, layout and mounting
arrangement.
The type of circuit design will be decided by Purchaser and specified in the PO. The control circuits
shall be designed for easy maintenance at location.

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5.7.2 Design
Valve control panels for on/off valves should be of “compact” type, avoiding internal tubing and
fittings. All accessories required for control of the actuator movement, such as hydraulic inlet filter,
solenoid valves, manual valves, pressure gauges etc. shall be mounted on a control panel.

Hydraulic oil inlet and outlet ports shall be clearly marked "Oil Inlet" and "Oil Outlet", both on control
panel and actuator. Isolation valves for supply and return lines shall be installed as close to the
instrument as possible.

Hydraulic filter units to be used shall have a differential pressure indication without an automatic
bypass function.

Pressure gauges shall indicate the internal pressure in the control unit.

Constant internal leakage shall not be designed into a control system, especially solenoid- and
hydraulic/pneumatic valves.

Oil-mist lubrication systems shall not be used unless required for special applications (gear motors
etc.).

Final layout arrangements proposed shall be confirmed and agreed by Company before fabrication.

5.7.2.1 Speed control

Devices for control of the speed in both directions shall be installed on the control unit as an
integrated part. It shall not be possible to fully close the restrictors. The restrictors shall be easy to
adjust during operation and shall include feasibility to car seal in any adjusted position.

5.7.2.1 Overpressure protection

Unless otherwise specified, a check valve shall be included in hydraulic circuit supply lines and
pneumatic supply lines. For hydraulically operated valves this check valve will cause a trapped-in
liquid volume in the actuator/control circuit. In case there will be a temperature rise in this liquid
volume (due to external heat input) the pressure may exceed allowable limits. To avoid this, a
combined check/pressure relief valve should be included. Alternatively, a small volume nitrogen
accumulator (nitrogen cushion separated from the oil by a diaphragm) can be used.

5.7.2.2 Accumulator
Unless otherwise specified, accumulators and their protection devices shall be assembled as a part of
the control circuit panel, to form a composite unit. If specified by Company they may also be required
as independent units, depending on the space available. The vent outlets from bursting discs must be
guided to a safe location.

5.7.2.1 Quick dump

Quick dump functionality may be considered when relevant to achieve necessary functional
requirements, e.g. fast operating time. Such functionality involves assisting the control medium to be
evacuated faster, typically during fail-safe operation. For saline and corrosive atmosphere conditions
the project/installation/plant shall consider features to recycle air/hydraulic fluid from the spring
chamber back to the control system, or otherwise prevent humid air and moisture from moving in and
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out of the spring housing. Such features should be considered in conjunction with “quick dump”
functionality of the actuator, and shall be specified in the PO.

5.7.3 Mounting
Control circuits shall, unless otherwise specified, be fitted onto free-standing support structures or
other fixed structures, i.e., with due attention made to conditions such as free line of sight to
valve/actuator and vulnerability during major incidents (fire 7 explosion) and falling objects.

Control circuits that are fitted directly onto actuators shall only be selected when access and
maintenance restrictions have been evaluated and concluded (by PO).

All mounting plates shall be protected by a shield along the top that completely covers all the control
circuit components.

Nuts / bolts used for fastening components in the panel with fastening on the rear side of the panel,
shall be fixed to the mounting plate and not drop off the rear during removal of individual components
for repair and maintenance.

All components required for controlling the movement of the hydraulic/pneumatic operated valves,
such as solenoid valves, pilot valves, manual valves, pressure indicators, air filter regulators, junction
boxes etc., shall be mounted onto a plate (min. 3 mm thickness) supported by angle framework. All
plate edges shall be rounded off to a minimum radius of 2 mm.

Control circuits for ESV valves and valves installed in exposed areas shall be mounted inside a
cabinet with a quick-lock hinged door with door stop. The width of the door shall not exceed 800 mm.
Drain plug(s) shall be provided in the cabinet base and plastic components shall not be used. When
mounted directly onto valve/actuator it shall be prepared for subsequent fire insulation by others.

Direct access shall be provided for calibration and maintenance of all instruments. It shall be possible
to remove individual components without having to remove inter-connected components (N/A for
“compact type”).

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6 Electrical operation

6.1 General
Requirements specified for electrical operation is default requirements. Other or additional
requirements may be specified in the PO.

The electric actuators may be considered used for "fail safe" applications based on final user
evaluations. This shall then be stated in the PO.

6.2 Design
The electric actuator shall be one integrated unit comprising an electric motor, gearbox, hand wheel,
reversing starter, local on/off control facilities, and local on/off/remote selector switch with padlock
facility. Hand wheel for manual operation shall be included as standard for electric actuators.

Each actuator shall have an individual performance test certificate stating the following recorded
parameters: Maximum torque, maximum torque current, flash test voltage, output speed or operating
time. The certificate shall also provide details of gear ratios and closing direction.

An option for fieldbus operation from the PCS system is required.

6.3 Electric motors

The electric motor shall be Class F insulated and rated for duty at an ambient temperature of + 40
deg C or specified maximum ambient, whichever is the highest, for a minimum of 15 minutes or twice
the valve stroking time, whichever is the longest, and with an average load of 33 % of the maximum
valve torque.

Electric motors shall be in accordance with the requirements as specified in TR3122 sections 2, 3.3,
3.4, 3.5 and 3.10.

6.3.1 Testing
Testing of electric motors shall be performed in accordance with TR3122 section 5.

6.3.2 Motor protection

Motor protection shall include trip at overheating and loss of one phase (3-phase motors).
The following functions to disconnect supply shall also be in place:
x Overload – Fuses are not allowed as overload protection. Protection with thermal image
distinguishing cold and hot condition shall be used.
x Short circuit – Fuses should be used in low voltage switchboards for short circuit protection.
Fuse selection criteria shall be defined, taking into account short circuit protection of consumer
and contactor in the starter/feeder, starting current versus starting time, and load current.
x Earth fault – The protection shall be active during motor start run up. Therefore a detection
system shall be used that is not sensitive to disturbance caused by starting current; reference
is made to IEC 60755 clause 8.10.

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x Stalled rotor – The overload protection can act as the stalling/locked rotor protection,
provided it can be documented that overload protection trip time is less than motor safe locked
rotor time.
x Undervoltage – Special undervoltage protection is not required for motors with contactor
voltage from bus bar. One common undervoltage protection relay per bus bar is acceptable,
distributing trip signal to all motors connected to the bus bar.

6.4 Torque and turns limitation

Torque shall at least be adjustable between the range 50% and 100% of rated torque. A torque
sensing system shall allow sufficient torque during unseating and mid travel restarting. The number of
turns shall be adjustable to suit the application.

6.5 Control facilities

The actuator shall have the possibility for the following modes of operation:
1. Remote electrically by signalling the actuator from the control system.
2. Local electrically by selecting local mode and operating pushbuttons on the actuator.
3. Local mechanically by releasing the electric motor via clutch and moving the actuator by a
standard hand wheel installed on the gear.
It shall be possible to set up the actuator to the following control modes through external individual
signal cabling:
x Open, Close and Stop with voltage free contacts NO and NC for limit switches.

On/off valves with electrical actuators shall have the possibility for serial communication.

Control of non-safety on/off valves (HV) with electrical actuators should be done with serial
communication links preferably using Foundation Fieldbus or profibus communication protocols.
Other communication protocols like modbus may also be considered but shall be evaluated by
Company.

6.6 Monitoring facilities

The following external monitoring shall be possible using individual signal cabling:
1) Local selector switch in Remote position
2) Actuator available for external control
3) Motor tripped

Local position indicator shall be included.

6.7 Hand wheels

Where hand wheels are specified, they shall conform to the following:

x May be integral or attached by bolts or clamps

x Shall be of locking type with de-clutchable hand wheel
x The maximum force of operation shall not exceed 250 N on the rim of the hand wheel
x Maximum diameter of hand wheels shall be 750 mm
x Shall be permanently marked "Open/Closed" with an arrow to indicate direction of rotation
x Engagement / disengagement shall be clearly indicated.

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7 Mechanical requirements

7.1 General
The valve/actuator assembly shall be designed to avoid high component stresses, instability between
valve and actuator, high deflections or other operational problems. The actuator shall be supported by
the valve. Supporting shall not be by adjoining pipe or other external structures unless this is agreed
between purchaser and supplier and included in the PO.

Junction- and limit-switch boxes, limit switches, position indicators and other ancillaries connected to
actuators, adapters and accumulators shall use rugged and solid methods for attachment.

The sizing of the actuator shall account for forces from a situation where the valve’s closing member
is prevented from free movement during a valve stroke. The drive chain shall be able to tolerate
maximum actuator output as defined in section 3.3.2.

When the valve/actuator will be installed oriented horizontally the stem deflection shall be considered
in the design and shall not be larger than 2 % of the stem diameter, measured at the stem-coupling.
Any spot check verification to be agreed between purchaser and supplier and included in the PO.

All valve assemblies including the control circuits may be specified to withstand explosion loads and
earthquake loads. Purchasers shall in the PO identify explosion load requirement by providing a
Design Accidental Load Specification that will identify blast loads for the various areas of a plant.

Flexible hoses may be used subject to Company approval. Alternatively, hard tube shall be installed
to allow safe operation due to relative movements of the actuator/accumulator during an explosion.

The actuator shall be provided with a local indicator showing the valve position at all times. Where fire
protection shield is applicable, valve position shall be visible outside such protection. When a
mechanical device/indicator is fitted, the Open and Closed positions shall be permanent/engraved.

All components that will require adjustments (e.g. piston end-stops, limit switches) shall use threaded
components for adjustment and locking.

Yoke and gear housings shall be completely weather proof. They shall be pre-lubricated for expected
life and oil filled housings shall be filled to submerge all moving parts.

Whenever rotary or linear shafts enter into a closed compartment (e.g. piston rods, limit switch shafts)
weather seals (lip-seal, O-ring) shall be fitted as flush as possible with the external surface. This is to
avoid entry of water and dirt.

The equipment shall be designed so that water does not accumulate in pockets/depressions on the
exterior, and is not trapped inside low-point volumes internally, causing corrosion. Drain facilities shall
be included if this is not possible to avoid.

External tie-rods on cylinders and spring cartridges shall be arranged such that there will be a
minimum distance between tie-rod and cylinder wall to enable adequate access for painting. The
minimum distance shall be 3,5mm for tie rods with a diameter smaller than 10mm and 5mm for tie
rods with a diameter larger than 10mm.

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7.2 Design of pressure retaining equipment

The specified design code shall be complied with fully, in addition to the requirements stated in
regional requirements for applicable location.

Design, fabrication, inspection and testing of hydraulic and pneumatic accumulators (air reservoirs)
and actuator cylinders shall be in accordance with EN 13445 and EN 14359.

The following alternative codes may be used if accepted by Company by CR:

x PD5500 Unfired Fusion Welded Pressure Vessels
x ASME Boiler & Pressure Vessel Code, Section VIII, Division 1 or 2

Unless type approval exist, Supplier is responsible for obtaining the necessary verification from a
recognised inspecting authority or organisation, for compliance with requirements in the applicable
design code, with regard to:
x Design verification
x Construction and testing

Air reservoirs and nitrogen systems shall be equipped with a pressure indicator and a rupture disc
overpressure safety device, designed according to BS 2915 or equivalent. Rupture discs shall not
face upwards and a safe gas outlet flow direction must be considered.

Multi-vessel accumulators shall be fitted with isolation valves to enable replacement of individual
vessels without de-pressurising the complete unit.

Threaded connections shall be used and the wall thickness of piping/tubing shall conform to relevant
maximum operating pressure and shall be calculated according to ASME B31.3

Hydraulic chambers shall have two ports located as far apart from each other as practicably possible
(i.e. on opposing sides of the cylinder and towards the highest and lowest points) to allow for efficient
flushing.

7.2.1 Hydraulic accumulator design

The hydraulic accumulators shall be of piston type, nitrogen charged, and mounted in vertical
position. All accumulators shall be equipped with a directly mounted local piston position indicator of
permanent magnet type. The upper and lower piston position limits, where proper function of the
whole system is verified, shall be marked clearly on the accumulator/indicator.

When specified by Purchaser in PO for critical services etc., the accumulators shall be equipped with
transmitters for continuous monitoring by the PCS system.

External nitrogen bottles, of standard size and material, according to design code BS 5045 Part 1,
shall be included where applicable. The accumulator's nitrogen system shall be equipped with an
easily operable nitrogen pre-charging arrangement. All valves in this service shall be of the soft
seated type.

Multi-vessel accumulators shall be designed to allow 1/3 of the total number of accumulator units to
be serviced with the remaining unit(s) in service.

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For all accumulators pre-charge graphs shall be made in accordance with requirements specified in
11.6.21 “Sizing and calculations”.

All nitrogen accumulators shall be delivered with wired-on AISI 316 SS tag plates giving information
about pre-charge pressures at temperatures 0, 5, 10 & 15 0C.

7.3 Springs
Spring and spring housing shall be designed paying careful attention to minimizing size and weight for
each application. The spring and spring housing shall be produced of materials resistant to corrosion
and/or be surface treated to minimize corrosion due to humid and corrosive atmosphere. Where the
actuator design is such that the volume inside the spring chamber varies as the valve is operated, the
spring housing shall be fitted with two ports located as far apart from each other as practicably
possible (i.e. on opposing sides of the cylinder and towards the highest and lowest points) to allow for
efficient flushing.

The spring shall be designed to operate through design lifetime. A minimum of 70 % of the effective
spring range shall be utilised.

Springs for fail safe actuators shall be designed for a 20 year life with a minimum of 2000 cycles with
less than 5 % loss of output (extended position). Springs shall be able to be fully compressed for two
weeks with the same output reduction.

Failure from fatigue shall not take place under the above conditions.

7.4 Adaptor stool

The adapter stool (connecting the actuator to the valve) shall be a tubular design having the same
moment of inertia in the longitudinal plane as in the transverse plane (planes intersecting through
valve stem). The tube diameter shall not be less than 40 % of the valve bonnet diameter.

A fabricated design of equal strength may be accepted by Company by a CR.

A ribbed design, e.g. T-ribs, with significantly unequal strength in longitudinal and transverse planes is
not acceptable.

Enclosed adaptor stools, and yoke and gear housings that may be pressurised by malfunction (e.g.
gas leaking through stem seals), shall be protected by a means to relieve over-pressure. The feature
shall ensure that any overpressure is relieved while no moisture is trapped inside.

7.5 Fire protection

Passive fire protection will generally be done by others, but Supplier shall provide requested
information enabling detailing of the necessary fire protection.

When fire protection is specified by Purchaser, Supplier shall include for this in the design and will
normally require the following:

x The equipment shall be prepared for fitting of the necessary clips etc. for attachment of fire
insulation in accordance with agreement between Purchaser and Supplier.

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x Fire protection shields must be designed to allow easy access to control units (hinged hatches are
acceptable) without removing a major part of the insulation.
x Control panels will typically be bolted on steel profiles positioned about 2000 mm above deck
level, therefore the bottom side of the panels must have necessary protection against jet fire and
explosion loads.
x Supplier shall provide all details required to ensure that the equipment, including all penetrations,
can be installed without degrading the integrity of the explosion- and fire proofing of the
equipment.
x Supplier shall provide all necessary certification of the explosion- and fire proofing design
(including any hatches and penetrations) from a recognised certifying authority e.g. Lloyds or
DNV.

7.6 Mechanical valve locking

When requested by Purchaser certain valves shall be fitted with a mechanical locking device. This
applies to any type of valve where the closing member may travel when the actuator is removed or
the power to the actuator is disconnected.

Example: Gate valves with the stem oriented vertically. Unwanted gate movement may occur due to
the weight of the stem/gate assembly or pressure inside valve/pipe may cause an opposite movement
of the gate.

7.7 Lifting lugs and eyebolts

All valves, actuators and valve assemblies with a weight ranging from 25 to 200 kg shall, as a
minimum, have an engineered solution, for strapping and lifting the equipment.

All valves, actuators and valve assemblies with a weight >200kg shall have a permanently fitted lifting
device fit for purpose.

The lifting devices are regarded as a part of the equipment and not a lifting appliance. A safety factor
of 4 shall be used when designing the lifting devices. Documentation of the calculations shall be kept
by the Supplier.

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8 Marking

8.1 Identification plates

Identification plates shall be of stainless steel and have a rectangular shape. Stainless steel drive
screws or stainless steel wire shall be the method of fastening the plates. Adhesives shall not be
used.

Accumulators shall have max/min marking of piston position.

8.1.1 Permanent identification plates

Actuators, and the control panels if they are separate, shall be furnished with permanent identification
plates, and the following information shall be shown as a minimum:
x Valve/actuator tag number
x Actuator serial number
x Operating pressure/Voltage
x Stroke (signal/range)
x Failure mode
x Operating medium

8.1.2 Temporary identification plates

Unless otherwise stated in the purchase order the valve shall additionally be supplied with a
temporary identification plate with the following information:
x PO Number
x PO Item Number

8.2 Tags and labels

8.2.1 Tag numbers

Tagging of all equipment, with service/operation description, shall be in accordance with Purchaser's
requirements and shall cover tagging for operation, maintenance and identification. The tag numbers
will also be reflected on the data sheets supplied by Purchaser in PO’s.

Purchaser shall issue a complete tag list covering all instruments and equipment items included in
each valve/actuator assembly (loop).

8.2.2 Tag labels

All tagged items, shall be equipped with a tag label to properly identify each of the components.

Tag labels shall be of stainless steel (excluding labels for junction/switch boxes and cables), and shall
have a rectangular shape. Minimum size shall be 50 x 20 mm x 0.4 mm. Letter- / figure size shall be
at least 10 mm. Stainless steel drive screws or stainless steel wire shall be the method of fastening
the plates. Adhesives shall not be used.

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In addition to the tag label described above there shall be an identical tag label made from Traffolyte
located adjacent (above) to each tagged item. This is to identify the location when the tagged item is
removed from its position

8.2.3 Language on signs

Signs and service designations on actuators shall for operational and maintenance purposes be
provided in the Native language. Dual language (Native and English) shall be used if the information
is vital to personnel safety, i.e. it relates to the use of emergency equipment, or it contains warnings
about hazards.

Other language requirements may be requested by Purchaser.

Standard name plates required by codes shall be in the English language.

8.2.4 Identification of junction boxes, switch boxes and cables

The tag numbers for junction boxes shall be engraved on white Traffolyte labels. The letters shall be
in black colour with a minimum size of 10 mm. The labels shall be pasted to the cover of the box
using a suitable adhesive, after the surface has been cleaned properly.

Identification sleeves for cables shall be of non-corroding type and fitted to each end of the cable, and
shall be labelled with instrument tag number / terminal number as appropriate and specified by
Purchaser.

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9 Testing and cleaning requirements

9.1 Inspections at supplier works

Company reserves the right to carry out inspections and witness tests at any time during
manufacture. The Supplier shall notify the Purchaser two weeks in advance of any scheduled
inspections and tests.

The Purchaser's representative shall have entry to all those parts of the Supplier's works, which are
concerned with the manufacture of equipment included in these technical requirements. They shall be
afforded all reasonable facilities to be satisfied that the work and goods are being supplied in
accordance with these technical requirements. This shall include all items of equipment subcontracted
by Supplier.

9.2 General testing requirements

All equipment and individual parts shall be delivered fully tested, in accordance with these technical
requirements, codes and data sheets, to guarantee the performance of the equipment.

The technical condition/ranges of all test equipment used for the different tests shall be capable of
verifying all requirements specified within this document.

All test equipment shall hold a valid calibration certificate. Hydraulic test rigs and pneumatic supplies
shall have sufficient capacity to meet the required performance of the valve assemblies and control
circuits as defined by purchaser.

The medium used in the main (piping) valve shall be potable water with chloride content less than 30
ppm with added corrosion inhibitor to protect the valve internals. The valve shall be cleaned and dried
after testing. Water shall not be used for valves that will be used in cryogenic service. Test medium
for such valves shall be agreed with purchaser.

Hydraulic test equipment shall be cleaned to ISO 4406, class -/14/10 prior to any test. An electronic
particle counter, or equivalent, with printout shall be used for documentation of the cleanliness level.

No Teflon tape or equal sealing material shall be used on test equipment.

All performed tests shall be recorded, indicating the actual results/figures.

The various tests can be combined where found advantageous and agreed with the Purchaser.

9.3 Functional tests

9.3.1 General
All units shall be individually subjected to a function test in accordance with specified requirements.
These may be manufacturers standard tests (subject to Purchaser's approval), but tests shall satisfy
the requirements defined herein.

x Valve test to verify leak, pressure, thrust/torque, etc.

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x Actuator test to verify performance, static pressure test, internal/external leak test,
cleanliness, etc.
x Control Circuit test to verify capacity, internal/external leak test, pressure test, function test,
cleanliness etc.
x Accumulator tests (third part verification, if applicable), leak and pressure tests, cleanliness,
etc.

All performed tests shall be recorded with their results, and records shall be presented upon request
by Purchaser.

9.3.2 Documents present at test stand

The following documents and drawings shall be present at function/factory acceptance tests:

x Purchaser’s Process Data Sheet

x Valve, Actuator and Control Circuit Dimensional Drawing
x Operating Diagram/Hook-Up Guidance for Control Circuits
x Test Procedures

The following documents shall be made available upon request:

x Purchaser’s Valve Data Sheet
x Actuator Sizing Calculations
x Accumulator Sizing/Capacity Calculations
x Valve Test Records/Certificates, (Torque/Thrust Figures)
x Actuator Test Records/Certificates, (Torque/Thrust Figures)
x Control Circuit Test Records/Certificates, (Leak/Static Pressure Test)
x Wiring Diagram, Limit Switches, Solenoids
x Test Rig Certificates, Cleanliness, Instrument Calibration Certificates
x Agreed Deviations
x Purchaser’s Instrument Data Sheet
x Documentation of conformance with IEC61511 and IEC61508 for the complete valve
assembly (e.g., FMEA, failure data, type approvals etc.), ref., also 11.8.

9.3.3 Leak test - hydraulic control equipment

All applicable units (actuators, control systems, accumulators) shall be leak tested for a period of
minimum 15 minutes after pressure stabilisation. A recorder shall be used. Test pressure shall be 110
% of maximum operating pressure.

Test-medium: Reference is made to 9.5.2.

Acceptance criteria: The system shall be considered approved when test-pressure decreases less
than 0.5 bar/15 min and there are no visible leaks or sweating.

9.3.4 Leak test - Pneumatic control equipment

All applicable units (actuators, control systems, accumulators) shall be leak tested with a soapy
solution, checking all fittings and connections. Test pressure shall be 110 % of maximum operating
pressure.

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Test-medium: Clean air or nitrogen.

Acceptance criteria: The units shall be considered acceptable when no leaks are found (bubble-tight).

9.3.5 Assembly tests - Adjustment settings

Thrust/torque verification, limit switch settings, dimensions, function, and identity shall be verified
against relevant documents and drawings.

The test shall include adjustment/control of stroke/alignment of valve, actuator and limit switches.
Correct operation of limit switches shall be verified.

The following tests shall be done unless otherwise agreed:

1. In the actuator/valve open position, the ZSH signal shall be positive. No signal shall be
indicated from ZSL. In the actuator/valve closed position, the ZSL signal shall be positive. No
signal shall be indicated from ZSH. Record results.
2. The assembly shall be stroked a minimum of 3 strokes for valves 14” and above and a
minimum of 5 strokes for 12” and below to verify repeatability. Travelling time to be monitored
and shall be on a steady level for the specified no of cycles to be accepted. Record results.

9.4 Factory Acceptance Tests (FAT).

9.4.1 General
All completed and assembled combinations of valve/actuator/control circuit/accumulator shall be
tested as described below.

9.4.2 Control circuit and valve assembly verification.

Check manufacturers individual test records for the control circuit, actuator and bare stem valve. All
tests as defined for the function tests shall be performed, utilising the dedicated control circuit to
operate the valve-assembly. The test shall verify the performance of the assembly, and confirm the
performance recorded during the FAT tests of the individual parts. The test shall also verify that the
selected actuator will operate the valve at minimum actuator supply pressure, with maximum
differential pressure across the valve.

1. Test 1 shall be performed with speed control valves in the fully open position. Apply maximum
differential pressure across the valve (as agreed with purchaser to be dimensioning for the
actuator sizing). The test shall include verification of the required valve torque/thrust with the
maximum differential pressure across the valve. This may be done by recording the necessary
pressure to operate the actuator and calculation of torque/trust (actuator internal friction to be
considered). The obtained value shall be compared with the torque/thrust result from the bare
stem valve test. No increase in torque/thrust shall be accepted. (If no bare stem test record is
available, the test result shall be compared with the theoretical valve requirements used for
actuator sizing). Record results and confirm the safety factor requirements as specified in
3.3.3.
2. Test 2 shall be performed with speed control valves in the fully open position. Repeat test1 at
minimum, normal and maximum supply pressure to control circuit/actuator. Record travelling
times.
3. Close speed control valves fully and operate the valve open/close at normal actuator supply
pressure. The valve shall complete the open/close stroke fully. Record travelling times.
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4. Apply normal supply pressure to the control circuit and set speed control to suit travelling time
requirements as defined in the Purchaser's IDS/PDS.
5. Verify fail safe operation of the valve/control circuit by simulating electric signal loss with the
maximum differential pressure applied across the valve. This step is meant to verify the
capability of the actuator to operate the valve to fail-safe position under the most onerous
condition. For fail-safe close valves the obturator can be placed in the “start-to-close” (i.e. the
point of travel where the obturator first starts to seal off the bore) position prior to the
pressurization and subsequent signal loss.

9.4.3 Accumulators/reservoirs verification

Ensure the correct nitrogen pre-charge pressure (related to actual temperature) in the hydraulic
accumulator prior to tests.

1. Set the valve in the "normal operating position" by pressurising the actuator/control circuit
using normal supply pressure.
2. Isolate and disconnect the hydraulic/pneumatic supply.
3. Cycle the valve 3 or 1.5 strokes, depending on the valve type (ref. section 3.4), by
energizing/de-energizing the control circuits solenoid valves as intended in the control circuit
functional design. Record actuator/control circuit supply pressure at start and end of test as
well as travelling times. All opening strokes shall be done with the specified maximum
differential pressure across the valve.
4. Verify fail safe operation of the valve/control circuit as per 9.4.2 step 5 if applicable.

Acceptance criteria: Accumulator/reservoir pressure shall not fall below the stipulated minimum
pressure after completion of the required test stroke cycles.

9.5 Cleaning and flushing

9.5.1 General
All surfaces in contact with hydraulic oil shall be machined. Raw as-cast or forged surfaces are not
permitted (cylinder end covers, pistons etc.).

Before shipment (after painting) all hydraulic equipment described in this document, including valve
actuators, shall be flushed to a cleanliness level according to ISO 4406 class -/14/10 or better.
Flushing shall be performed in accordance with a written flushing-procedure, conforming to
requirements specified in NS 5910. The procedure shall be submitted to Company for review.
Supplier shall purchase all hydraulic main components with a documented cleanliness level according
to this standard. These components shall be by-passed during assembly system flushing, so as not to
contaminate already cleaned components.

Storage, handling and assembly of the actuator parts shall be such to prevent any ingress of foreign
material and pollution. The specified hydraulic oil shall be the only lubricant used during assembly of
the hydraulic cylinder, piston, rod and seals.

An electronic particle counter, or equivalent, with printout shall be used for documentation of the
cleanliness level.

Maximum allowed water content shall be less than 50 % of the relative saturation at + 20 0C.

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The interface fittings between flushing equipment and equipment to be flushed shall conform to the
specified project instrument tube-fittings for the control system. After completed flushing these fittings
shall not be removed, but plugged by nominated instrument fittings, to maintain the cleanliness
requirements. Labels shall be attached to these sealing fittings with the following text: "System
flushed to ISO 4406, class -/14/10. Only to be removed by authorised personnel".

9.5.2 Hydraulic oil

Hydraulic oil type STATOIL HYDRAWAY HVXA-15 LT, or equivalent compatible Company approved
hydraulic oil shall be used for all tests and flushing.

In some applications synthetic hydraulic oil will be used. This will be specified by Purchaser in the PO.

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10 Surface protection

10.1 General
All surface protection shall be according to TR0042.

When coating is specified, all external surfaces shall be coated. An external surface is a surface that
will be exposed to the atmosphere after the valve/actuator/gear box is assembled.

In the event that coating inspectors qualified to NACE, FROSIO or ICorr as specified are not
available, Company can consider accepting alternative qualification of inspectors from the painting
shops. The acceptance shall be formalized by a CR including documentation of alternative
qualification. The approval of the CR may require a verification of the paint shop and will be agreed
from case to case. The quality of the coating work will be followed closely and any failure to meet
quality requirements following alternative inspector qualification acceptance may lead to withdrawal of
the concession.

10.2 Colours
Unless otherwise specified the following colours shall be used:

For valves and accessories the colour shall be RAL 7035.

For actuators colour coding is depended on failure action:

x Fail open: RAL 6002 (green)
x Fail close: RAL 3000 (red)
x Fail lock: RAL 7035 (grey)

Nitrogen bottles shall have the colour green.

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11 Documentation including Life Cycle Information (LCI)

11.1 General
Documentation including Life Cycle Information (LCI) shall be supplied in accordance with TR2381,
TR0052 (applicable for project specific documentation) and additional requirements specified herein.

The Supplier shall incorporate details of sub-supplier scope in their own LCI.

Company’s acceptance of Supplier’s documentation does not constitute approval in the sense that
Company assumes responsibility for the correctness of the contents.

Documentation from actuator supplier shall not be modified or added new or different drawing frames
as this will reduce readability of the documentation. If required, valve supplier logo, contractor logo
and document numbering other than the numbering given by the actuator supplier shall be added on
the original document format located on available free space or as an additional front page. Page
numbering shall not be revised.

11.2 General requirements for all procedures

All procedures shall in a condensed and concise manner:
x Include the scope and purpose of the document.
x Include all Company specific requirements.
x Detail all relevant operations, checks and tests.
x Describe all precautions to be observed.
x Include relevant health warnings related to chemicals used etc.
x Include sub-suppliers data sheets.

Procedures shall be self-explanatory, avoid making reference to other support documents.

11.3 Bid documentation

The bid shall at least include the following information:

x Supplier Master Information Register (SMIR)

x Interface information, given on GA drawings or tabulated in a spreadsheet, and at least
containing the following information:
x height, center line to top (if supplied as part of a valve assembly)
x maximum overall dimensions (L x W x H)
x dry weight
x Design and operation information
x List of technical and commercial deviations from the requirements in the inquiry, and proposed
alternative requirements.
x Reference list
x Typical production plan (EPMS)
x List of proposed sub-suppliers
x Confirmation of adequacy for use in safety application, when relevant.
x Additional bid information as required by Purchaser

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In case of an order, SMIR, production plans (EPMS) and list of proposed sub-suppliers shall be
resubmitted and included in the LCI.

11.4 Supplier Information Requirement List (SIRL)

The Supplier Information Requirements List (SIRL) given below comprises documentation
requirements additional to TR2381. The documents listed below are needed in the Project phase in
order to ensure correct quality of delivered valve assemblies. These documents shall not be stored in
SAP, and may be disposed by Purchaser when the valve assemblies have been taken into use.

Submittal time shall be agreed with project.

Table 5 - Supplier Information Requirements List (SIRL)

Required in Project
Required in Bid
Document description

BID DOCUMENTATION
Supplier Master Information Register – (SMIR) Y Y
Interface information Y
Design and operational information Y
List of "commercial exceptions/clarifications to inquiry documents" Y
List of "technical exceptions/clarifications to inquiry documents" Y
Reference list Y
Production Plan Y Y
Quality Control Plans Y Y
List of proposed sub-suppliers (incl. record of qualifications) Y Y
Additional bid information as required by Purchaser Y
PROJECT DOCUMENTATION
Tag – Document information Y
Welding Procedures (WPS + PQR) Y
NDE procedures Y
Aluminium Specification Y
Painting Procedure(s) Y
Performance / functional test procedures and reports Y

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Required in Project
Required in Bid
Document description

Mechanical Completion / Commissioning Dossier Y

Preliminary GA drawings containing maximum outer dimensions shall be issued as early as possible
in agreement with purchaser. The document shall specify guaranteed maximum dimensions
(Tolerances typically + 0mm / - 50 mm) for the actuators. These dimensions will be used for space
allocation in the piping 3D model design. Exact dimensions shall be confirmed in drawings as per
TR2381 §5.218.

11.4.1 Supplier Master Information Register (SMIR)

SMIR shall give a detailed listing of indexes, drawings and documents with schedule for submittal.
The SMIR should be in Excel format and shall be used and maintained by the Supplier. A different
format may be used as long as all the columns in the template above are used. The SMIR shall not be
set in status 1 before the finalization of the order, and shall be re-submitted to Purchaser whenever its
content is changed.

11.4.2 Production plan

The production plan shall contain the main production activities and shall include actual dates.

11.4.3 Quality Control Plans (QCP)

A separate Quality Control Plan (QCP) shall be made for each equipment design, but the various
plans may be compiled into one document. The QCP shall include references to relevant documents
including MDS. All applicable tests and inspections shall be included in the plan. The QCP shall make
reference to acceptance criteria, and include witness (W), review (R) and hold (H) points.

11.4.4 Performance / functional test procedures and reports

The following performance / functional test procedures and reports are required:
x FAT including pressure testing

Test procedures shall include, but not be limited to:

x Description and sequence of tests to be conducted
x Responsibilities
x Equipment used (clamping, instrumentation, etc.)
x Test pressures
x Test duration
x Acceptance criteria
x Description of test documentation

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For intelligent positioners with 4-20 mA input and HART or Fieldbus communication and diagnostic
possibilities, a documented footprint/valve signature from the FAT shall be delivered electronically in a
readable file format.

11.4.5 NDE procedures

A separate procedure shall be submitted for each method. The NDE procedure(s) shall at least
describe:
x Scope
x Description of methods
x For radiographic examination of castings; sketches showing sections to be examined
x For ultrasonic examination; sketches showing scanning pattern
x Equipment to be used
x Personnel qualification
x Applicable standards
x Acceptance criteria
x Reporting

11.4.6 Aluminium specification

The specification shall include standard and grade, manufacturing and delivery condition, testing,
NDT, certification, manufacturer(s), etc. The connection details to other components, to avoid
possible galvanic corrosion, shall be described.

11.4.7 Welding procedures

Welding procedures (WPS + PQR) shall comprise:
x Approved welding procedure specifications
x Welding procedure qualification records
x Standards

11.4.8 Painting procedure(s)

A coating system data sheet (CSDS) shall be prepared for all coating systems. The CSDS shall
include at least the following information for each product:
x Surface pre-treatment requirements
x Film thickness (maximum, minimum and specified)
x Maximum and minimum re-coating intervals at relevant temperatures
x Information on thinners to be used (quantities and type)
x Coating repair system

A detailed coating procedure specification (CPS) shall be established. The CPS shall contain the
following:
x Identification of equipment for surface preparation and application
x Information given on coating system data sheet
x Personnel protective equipment to be used
x Safety data sheets for each product
x Product data sheets

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The CPS shall be re-qualified if there is any change in coating material or any change of method and
equipment for surface preparation and coating application.

11.5 Mechanical Completion / Commissioning Dossier

The mechanical completion (MC) dossier shall be recorded in Procosys as specified by the
project/installation.

11.6 Safety Integrity and Reliability Requirements

Safety Integrity and Reliability Requirements shall be as per TR2381 section 5.166.

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12 Additional requirements
Definitions and abbreviations

12.1.1 Definitions
“Company” means Statoil or The Group for projects with more than one owner.
"Purchaser" means any other party issuing the PO to Supplier.
“Supplier” means the party who supplies or manufactures equipment against the PO from
Purchaser.
“Drive chain” means all parts and components of a valve drive between the operator
(actuator) and the valve’s closing member, including the closing member but
excluding the operator.

12.1.2 Abbreviations
AFFF Aqueous Film Forming Foam
ASME American Society of Mechanical Engineers
ASTM American Society for Testing and Materials
BDV Blow Down Valve
BS British Standard
BSPP British Standard Pipe Parallel thread
CPS Coating Procedure Specification
CSDS Coating System Data Sheet
CSO Car Seal Open
CSC Car Seal Close
CR Concession Request
DNV Det Norske Veritas
DP Differential Pressure
ESD Emergency Shut Down
ESV Emergency Shutdown Valve
EPMS Engineering Procurement Manufacturing Schedule
FAT Factory Acceptance Test
FMEA Failure Modes and Effects Analysis
GA General Arrangement
GRP Glass-Reinforced Plastic
HIPPS High Integrity Pressure Protection System
HV Hand Valve, actuated, controlled by PCS
HP High Pressure
IDS Instrument Data Sheet
IEC International Electrotechnical Commission
IP Ingress Protection
ISO International Organization for Standardization
LCI Life Cycle Information
LED Light-Emitting Diode
MC Mechanical Completion
NACE National Association of Corrosion Engineers
NDE Non Destructive Examination
NEK Norwegian Electrotechnical Committee
NPT National Pipe Thread

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NS Norwegian Standard Association

OLF The Norwegian Oil Industry Association
PED Pressure Equipment Directive
PO Purchase Order
PCS Process Control System
PDS Process Data Sheet
PSA The Petroleum Safety Authority Norway
PSD Process Shut Down
PQR Procedure Qualification Report
QCP Quality Control Plan
SAS Safety and Automation System
SMIR Supplier Master Information Register
SIRL Supplier Information Requirement List
SPV Simple Pressure Vessels
VDS Valve Data Sheet
WPS Welding Procedure Specification
XV Process Shutdown Valve, controlled by PSD
ZSH Position switch high
ZSL Position switch low

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12.2 Changes from previous version

Section: Change description:

3.2 Valve Operating Speed Maximum ESD travel time changed from 1 to 2 sec/inch. Re-
phrased as per TR1055.
3.3.2 Actuator Sizing Added opening to use pressure reduction feature.
4.1 General Added opening for using aluminium for actuator housing.
4.3 Actuators – Table 1 Added that hand wheels shall not be made from tin.

4.5 Tagged Instruments Changed purchase of solenoid/control valves from nominated

list to specified by project/installation plant.
4.5 Tagged Instruments – Table 2 Plastic added as alternative for position indicator.

4.6 Instrument commodity items Tubing changed to base case 6Mo or 25% Cr Duplex.
Alternatives materials for tubing, fittings and commodity items
clarified.
4.8 Static environmental seals Paragraph added.
5.2 Supply utilities – Electrical supply Specific voltage, phase and frequency requirements deleted.
5.6.2.2 Hydraulic and Nitrogen 316 SS/NBR added as alternative for seal packing.
services
5.6.5 Junction boxes Entry point requirements clarified.
5.7.2.1 Quick dump Paragraph added.
6.3 Electric motors References to TR3122 added. Paragraphs 6.3.1 and 6.3.2
added.
6.5 Control facilities Modes of operation added.
7.1 General Added requirement for actuator sizing to take account for
operation with blocked valve.
7.2 Design of pressure retaining 1. Rupture disc orientation requirement added.
equipment 2. Requirement for hydraulic chamber flushing ports added.
7.3 Springs Requirement for flushing ports added.
9.4.2 Control circuit and valve Added requirement for fail-safe test with full differential
assembly verification – 5 pressure in valve.
9.4.3 Accumulators/Reservoirs Bullet point 4 added.
verification
10.1 General Specific requirements removed and referred to TR0042.
10.2 Colours Colour for nitrogen bottles added.
11. Documentation including LCI Section reworked.
App A/App B 1. Changes reflected on schematic drawings.
2. References to legends added.
App C – C1 Design of equipment Paragraph regarding ATEX added.
App C – C2 Pressure rating Removed.
App E Added.
App F Added.

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12.3 References
All work specified, shall where referred be strictly in the accordance with applicable sections of the
latest editions of the following general or regional codes, standards and regulations (and their current
amendments):

Referred std. Description

APOS DW-T10-01 Surface Wellhead and Christmas Tree System
ASME VIII Boiler & Pressure Vessel Code, Section VIII, Division 1 and 2
ASME B1.20.1 Pipe Threads, General Purpose (Inch)
ASME B1.20.2M Pipe Threads, 60 deg. General Purpose (Metric)
ASME B31.3 Process Piping
ASTM A153 Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel
Hardware
BS 2915 Bursting discs and bursting disc devices
BS 5045 Part 1. Spec. for seamless steel gas containers above 0,5 litre water
capacity
DIN 3852 Ports and stud ends with metric fine pitch thread, for use with compression
couplings, valves and screw plugs; Dimensions
EN 286-1 Simple unfired pressure vessels designed to contain air or nitrogen - Part 1:
Pressure vessels for general purposes
EN 13445 Unfired Fusion Welded Pressure Vessels
EN 14359 Gas Loaded Accumulator for Fluid Power Applications
EU Directive Pressure Equipment Directive (PED)
EU Directive ATEX, concerning equipment and protective systems, intended for use in
potentially explosive atmospheres, shall apply
EU Directive Simple Pressure Vessel Directive (SPV)
EU Directive EN 292-1 and EN 292-2 Safety of Machinery
IEC 60079 Explosive atmospheres
IEC 60529 Classification of degrees of protection provided by enclosures
IEC 60947-5-6 Low-voltage switchgear and control gear
IEC 61508 Functional safety of electrical/electronic/programmable electronic safety
related systems
IEC 61511 Functional safety – Safety instrumented systems for the process industry
sector
ISO 228-1 Pipe threads where pressure-tight joints are not made on the threads - Part
1: Dimensions, tolerances and designation
ISO 1179-2 Connections for general use and fluid power - Ports and stud ends with ISO
228-1 threads with elastomeric or metal-to-metal sealing - Part 2: Heavy-
duty (S series) and light-duty (L series) stud ends with elastomeric sealing
(type E)
ISO 1461 Hot dip galvanized coatings on fabricated iron and steel articles -
Specifications and test methods
ISO 4406 Cleanliness Requirements of Parts Used in Hydraulic Systems
ISO 5210 Industrial Valves – Multiturn valve actuator attachments
ISO 5211 Part 1/2/3 Part turn valve actuator attachment
ISO 12490 Petroleum and natural gas industries – Mechanical integrity and sizing of
actuator and mounting kits for pipeline valves
NEK 606 Cable for Offshore Installation
NORSOK M-650 Qualification of Manufacturers of Special Materials

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Referred std. Description

NS 5910 Cleaning of Hydraulic Pipe Systems
OLF 070 Guidelines for the Application of IEC 61508 and IEC 61511 in the petroleum
activities on the continental shelf
PS Regulations concerning process and auxiliary facilities in petroleum
activities Regulation concerning safety and communication systems on
installations in the petroleum activities
PSA Regulations concerning explosion and fire protection of installations in the
petroleum activities
PD5500 Unfired Fusion Welded Pressure Vessels
TR0034 Subsea X-mas Tree and Completion/Workover Riser Systems
TR0042 Surface preparation and protective coating
TR0052 Statoil engineering numbering system (ENS)
TR1236 Subsea Production System valves and large HP valves in pipeline
transportation systems
TR1830 Surface Wellhead and Christmas Tree System
TR1956 Non-conventional pressure protection systems
TR2000 Piping and Valve Material Specification (Statoil internal specification)
TR2212 Control & Choke Valves
TR3010 Mechanical, Technical Requirements and Standards
TR3032 Field Instrumentation
TR3023 Electrical, instrument and telecommunication installations, offshore units
Electrical, instrument and telecommunication installation, onshore plants
TR3024
TR2381 LCI Requirements

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App A Control circuits (normative)

Table 6 - Control circuits (normative)

Link to: Control units

Type Drawing
Control Circuit Description Drawing No.
No. Rev.
1 Pneumatic Single Action, PSD or PCS Service mser1300-cc01.tif B
2 Pneumatic Single Action, ESD and PSD or PCS mser1400-cc02.tif B
Service
9 Electr./hydr. Single Action, PSD or PCS Service mser2100-cc09.tif D
10 Electr./hydr. Single Action, ESD and PSD or PCS mser2200-cc10.tif D
Service
11 Electr./hydr. Double Action, PCS Service mser2300-cc11.tif D
12 Electr./hydr. Double Action, PSD or PCS Service mser2400-cc12.tif C
13 Electr./hydr. Double Action, ESD and PSD or PCS mser2500-13.tif C
Service
14 Pneumatic Single Action, ESD (blowdown) and PCS mser2600-cc14.tif B
Service
17 Electr./hydr. Single Action, ESD (blowdown) and PCS mser2900-cc17.tif D
Service
18 Electr./hydr. Double Action, ESD (blowdown) and PCS mser3000-cc18.tif C
Service
24 Elec./hydr. Double Action, PCS service(inching for pig mser1400-cc24.tif 0
launcher control)

Note:
Optional circuits as listed in App. B or alternative functions might be required. Selected control circuit
will be defined by Purchaser in PO.

Legends:
Pumps, Compressors, Filters, Control Mechanisms C999-ST-R-LF-0001-01
Connectors and Joints Control Valves, Miscellaneous C999-ST-R-LF-0001-02
Actuators, Equiment, Signals Function Blocks C999-ST-J-LF-0001-03
Line Symbols, Signals and Line Styles C999-ST-P-LF-0001-07

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App B Optional control circuits (informative)

Table 7 – Optional control circuits (informative)

Link to: Control units

Type Drawing
Control Circuit Description Drawing No.
No. Rev.
3 Pneum./hydr. Single Action, PSD or PCS Service mser1500-cc03.tif D
4 Pneum./hydr. Single Action, ESD and PSD or PCS mser1600-cc04.tif D
Service
5 Pneum./hydr. Double Action, PCS Service mser1700-cc05.tif D
6 Pneum./hydr. Double Action, PSD and/or PCS mser1800-cc06.tif D
Service
7 Pneum./hydr. Double Action, ESD and PSD or PCS mser1900-cc07.tif D
Service
8 Hydr. Manual Operation, PCS Service mser2000-cc08.tif C
15 Pneum./hydr. Single Action, ESD (blowdown) and mser2700-cc15.tif D
PCS Service
16 Pneum./hydr. Double Action, ESD (blowdown) and mser2800-cc16.tif D
PCS Service
20 Pneumatic Double Action, ESD or PSD or PCS mser1400-cc20.tif 0
service
21 Pneumatic Double Action, ESD and PSD or PCS mser1400-cc21.tif 0
service
22 Elec./hydr. Double Action, ESD or PSD or PCS mser1400-cc22.tif 0
service(high volume/capacity for large gate valves)
23 Elec./hydr. Double Action, ESD and PSD or PCS mser1400-cc23.tif 0
service(high volume/capacity for large gate valves)

Note:
Optional control circuits, selection will be defined by Purchaser in PO.

Legends:
Pumps, Compressors, Filters, Control Mechanisms C999-ST-R-LF-0001-01
Connectors and Joints Control Valves, Miscellaneous C999-ST-R-LF-0001-02
Actuators, Equiment, Signals Function Blocks C999-ST-J-LF-0001-03
Line Symbols, Signals and Line Styles C999-ST-P-LF-0001-07

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App C Applicable for valves supplied to the European Community (normative for
applicable area)

C.1 Design of Equipment

The specified design codes shall be complied with fully, in addition to the requirements stated in
relevant EU Directives (PED, ATEX, SPV, Safety of Machinery, Etc.).

For small industrial standard pressure vessels with design pressure (PS, bar) less than 10 bar g and
having a product of PS and V (volume, litre) less than 25 for gas and 200 for liquids, and having an
approved type examination according to PED, any of the referred codes may be used without
additional requirements.

For small standard pressure vessels for air and nitrogen, EN 286-1 Simple Unfired Pressure Vessel
Designed to Contain Air and Nitrogen, may be used without any additional requirements.

ATEX – Directive 94/9/EC

For electrical equipment (e.g. electrical actuators and control circuits) conformance to the Directive
shall be issued by a Notified Body in accordance with 94/9/EC Annex III. However, for hydraulic
actuators, pneumatic actuators and assembled units (e.g. actuated valves) the manufacturer can affix
the CE marking and draw up a written declaration of conformity according to Annex VIII of the
Directive.
As stated in ATEX Guidelines section 5.2.1 the Directive is not applicable for pressure relief valves
and hand operated valves.

C.2 Marking
The name plate shall in addition to specified marking be marked with:
x CE approval

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App D Applicable for valves supplied to Norway or Norwegian part of continental

shelf (normative for applicable area)

D.1 Design of equipment

The specified design codes shall be complied with fully, in addition to the requirements stated in
relevant EU Directives and national regulations.

The following is relevant but others may be identified in PO:

x NEK 606 Cable for Offshore Installation
x OLF 070 Guidelines for the Application of IEC 61508 and IEC 61511 in the
petroleum activities on the continental shelf
x PS Regulations concerning process and auxiliary facilities in petroleum
activities
Regulation concerning safety and communication systems on installations in
the petroleum activities
x PSA Regulations concerning explosion and fire protection of installations in
the petroleum activities

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App E Applicable for valves supplied to Snorre A

E.1 Environmental data

Ambient temperature: +23 °C / -8 °C

E.2 Instrumentation
Signal Types:

Solenoid valves EX(m), End connection EExi 24VDC

Air Supply:

Min. oper. pressure: 4 bar g

Nominal oper. pressure: 7 bar g
Maximum oper. pressure: 10 bar g
Design pressure: 10 bar g

Electrical Supply:

230V AC / 3-phase / 60Hz

660V AC / 3-phase /60Hz (Note: Vigdis)

Actuator control circuits:

The control panel is not part of the valve supplier scope of work, but the valve supplier is
responsible for informing the project of all necessary interface data relevant to the control panel
manufacturer. This data shall include flow rates, max. and min. pressure conditions, interface
connection sizes, and mounting details to allow for mounting and control panel on the actuated
valve unit.
Typical schematic control circuits for hydraulic and pneumatic actuated valves for Snorre A
shown in section E.7.

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E.3 Actuator selection and sizing

Actuator selection – philosophy:

Choice Tag / action Actuator type Remarks

no.
1 ESV, XV, BDV, HV Hydraulic actuator with spring return New philosophy
Fail safe action
2 ESV, XV, BDV, HV Hydraulic actuator, double acting incl. ‘Old’ SNA philosophy
Fail safe action accumulator

1 HV Electrical actuator
Fail lock action
2 HV Hydraulic actuator excluding If favourable vs electrical
Fail lock action accumulator actuator due to signal
infrastructure, size, price etc.

X Pneumatic actuator Shall normally not be

selected. Company approval
required.

Actuator sizing factor for tag ESV, XV and BDV:

Due to space restrictions which may occur, and actuator sizing factor between 1.5 and 2 may be
accepted. Company approval required.

E.4 Documentation requirements

TR1043 LCI Requirements – Snorre specific amendments shall govern.

E.5 Nominated manufacturers

Actuators:

Hydraulic actuator – spring return Rotork UK

Hydraulic actuators – double acting Oceaneering Rotator AS / Scana Skarpenord
Electrical actuators Rotork UK

Tagged instruments:

Solenoid valves – hydraulic Oceaneering Rotator Norway AS 316 SS

Solenoid valves – pneumatic Lucifer UK 316 SS

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Governing document: Valve Actuators Classification: Internal

Instrument commodity items:

Air filter regulator Fairchild 316 SS

Instrument fittings Swagelok 316 SS
Instrument manifolds Swagelok 316 SS
Instrument valves Swagelok 316 SS

E.6 References
/1/ TR1967 Technical and Professional Requirements, Snorre A
/2/ WR1246 Testing of Emergency – Shutdown and Blow Down Valves
/3/ WR 1759 Testing and Inspection of Safety Instrumented Systems

E.7 Typical control circuits

S1-AA-PAT-0006 P&ID diagram legend instrumentation typical detail valves I

S1-AA-PAT-0007 P&ID diagram legend instrumentation typical detail valves II
S1-AA-PAT-0008 P&ID diagram legend instrumentation typical detail valves III

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App F Applicable for valves supplied to Gullfaks

F.1 Environmental data

Field material and equipment shall be designed for the following weather conditions (ref. TR0024
General Amendment Gullfaks), unless otherwise specified:

Summer Winter
Ambient air temperature: +20 °C max -3 °C min
Ambient air humidity: 90% R.H. max 90% R.H. max

Wind conditions
Predominant wind direction: WSW
Wind speed: 20 m/sec

F.2 Instrumentation
General:

Equipment installed in non-hazardous naturally ventilated areas shall comply with a level of explosion
protection according to hazardous area zone 2 requirements as a minimum.

Preferred Ex protection methods shall to maximum extent possible be:

x Ex I for field instruments and solenoid valves

Ex m for solenoid valves may be used.

Limit switches:

When replacing an existing valve, the new limit switches shall have equal electrical signal interface to
the control system as the old switches to prevent modifications to the SAS.

Mechanical details and workmanship:

Work with tubing and compression fittings:

Field instrument hydraulic connections shall as a minimum be ½” NPT female connections.

If accumulators cannot be supplied with NPT ports, accumulators with BSPP ports are allowed limited
to first process connection.

Actuator control circuits:

Schematic control circuits for hydraulic/pneumatic actuated valves shall be as defined in STIDDoc
GFX-1-000-JT-101-01 to GFX-1-000-JT-118-01.

Valve control panels for on/off valves of compact type shall not be used.

The need for installing control circuits into a cabinet shall be approved by Company prior to purchase.

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from 2012-10-01
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Governing document: Valve Actuators Classification: Internal

Hydraulic operated valves with a check valve in the circuit supply line shall have a small volume
nitrogen accumulator included to allow for thermal expansion in trapped volume.

F.3 Mechanical requirements

Mechanical valve locking:

SO0501 “Bruk av aktuatorstyrte ventiler som barrierer” Section 2.2 gives guideline to which valve type
that should have a mechanical valve locking device installed.

Project development (PD), Technical and professional requirement, TR0038, Final Ver. 3, valid
from 2012-10-01
Page 49 of 49
Validity area: Corporate technical requirements/On- and offshore