7 254625-300-sp-int-024 specifications for motor...

$: 7 254625-300-SP-INT-024 Specifications for Motor …tenders.hpcl.co.in/tenders/tender_prog/TenderFiles/2304/Tender... · Protocol with final change\7_254625-300-SP-INT-024 Specifications$
VISAKH MARKETING INSTALLATION RESITEMENT

PROJECT - BLACK OIL TERMINAL

Doc No:254625-300-SP-INT-024 Rev: B Page 1 of 21

P:\Andheri\IndiaProject\254625 HPCL- Black Oil Terminal\05 Control & Automation\Documents\Document\Specifications\Package - II\With Open

Protocol with final change\7_254625-300-SP-INT-024 Specifications for Motor Operated Control Valves.doc

SPECIFICATIONS

FOR

MOTOR OPERATED CONTROL VALVES

Hindustan Petroleum Corporation Ltd

Visakha Dispatch Station

VR-ATP Area, Naval Base Post

Visakhapatnam - 530 014

Andhra Pradesh

Mott MacDonald Consultants (India) Pvt. Ltd.

Kothari House, CTS No. 185

Off Andheri - Kurla Road

Andheri (East)

Mumbai 400 059






SPECIFICATIONS

FOR

MOTOR OPERATED CONTROL VALVES

Client HINDUSTAN PETROLEUM CORPORATION LTD.

MMCI Project No. 254625

Issue and Revision Record:

Rev Date Originator Checked Approved Description

A 19.06.09 HVS AYM RM Issued for Approval

B 01.09.09 HVS AYM RM Issued for Approval.

C

Group Disclaimer

"This document has been prepared for the titled project or named part thereof and should not be relied upon or used for

any other project without an independent check being carried out as to its suitability and prior written authority of Mott

MacDonald being obtained. Mott MacDonald accepts no responsibility or liability for the consequences of this document

being used for a purpose other than the purposes for which it was commissioned. Any person using or relying on the

document for such other purpose agrees, and will by such use or reliance be taken to confirm his agreement, to

indemnify Mott MacDonald for all loss or damage resulting therefrom. Mott MacDonald accepts no responsibility or

liability for this document to any party other than the person by whom it was commissioned.






List of Contents Page

1 INTRODUCTION 5

2 APPLICABLE, CODES, STANDARDS & SPECIFICATION 5

2.1 General 5

2.2 Codes and Standards 5

2.2.1 International Codes 5

2.2.2 National Codes 6

2.2.3 IBR Certification 6

2.3 Deviations to Specification 7

2.4 Conflicting Requirements 7

2.5 Associated Project Documentation. 7

2.6 Abbreviations & Terminology 7

3 PLANT LOCATION 8

4 Hazardous Area Classification and Protection 8

5 Utilities Specification 8

6 SCOPE OF SUPPLY 8

7 CONTROL VALVE 8

7.1 Design & Construction 8

7.2 Seat Leakage 10

7.3 Minimum Rangeability 10

7.4 Packing & Gaskets 10

7.5 Bonnets 10

7.6 Materials 11

7.7 Noise 11

7.8 Trim Design 11

7.9 Accessories 11

8. MOTOR OPERATED CONTROL VALVE SYSTEM 12

9 IDENTIFICATION 18

10 INSPECTION AND TESTING 18

10.1 Hydrotest 18






10.2 Seat leakage test 18

10.3 Functional Test 18

10.4 Test & Test Certificate 19

11 SPARES AND SPECIAL TOOLS 19

12 BIDDER DOCUMENTATION 19

12.1 Information to be supplied with offer 19

12.2 Information to be supplied after LOI/PO 20

12.3 Final Documentation 20

13 TRANSPORTATION AND STORAGE 20

14 GUARANTEE 21

15 SITE SERVICES 21






1 INTRODUCTION

This specification covers the minimum requirements for the design, manufacture, assembly,

inspection, testing, certification, packing and delivery of Motor Operated Control Valves for

Hindustan Petroleum Corporation Ltd. (HPCL) for Terminal Automation of “Visakh Marketing

Installation Resitement Project – Black oil Terminal”.

The following definitions shall apply for this specification:

Definitions:

Owner : Hindustan Petroleum Corporation Ltd.

Consultant : Mott MacDonald Consultants (India) Pvt. Ltd.

Bidder /

Manufacturer

: Control Valve Manufacturer & Supplier

Engineer In-

charge

: Means the Resident Engineer or a person acting on behalf of

HPCL/MMCI at site

Shall : This is to be understood as a mandatory in relation to the

requirements of this document

Should : This is to be understood as a strong recommendation to comply

with the requirements of this document.

2 APPLICABLE, CODES, STANDARDS & SPECIFICATION

2.1 General

The items shall be designed and supplied in accordance with this specification and the codes and

standards referenced herein.

The design, manufacture, assembly, inspection, testing, certification and delivery of control valves

shall be in accordance with the latest edition of the codes, specifications and standards (including

standards / specifications mentioned therein) listed in this requisition.

It is assumed that the standards and specifications listed below are in the Bidder’s possession.

2.2 Codes and Standards

The control valves shall meet but not be limited to the latest edition or revision of the following

codes and standards.

2.2.1 International Codes

The selection of material and equipment, and the design and construction of the equipment covered

by this specification shall comply with the applicable edition of the references in effect at the time

of the Purchase Order and as noted throughout this specification.

API 598 2004 Valve Inspection and Testing.

API -6FA 1999 Specification for Fire test for Valves.






ASME B1.20.1 1983 Pipe Threads, General Purpose (inch)

ASME B16.5 2003 Steel Pipe Flanges and Flanged Fittings

ASME B16.10 2000 Face-to-Face and End-to-End Dimensions of Valves

ASME B16.34 2004 Valves – Flanged, Threaded, and Welding End

ASME B31.3 2004 Chemical Plant and Petroleum Refinery Piping

EN 50018 2000 Electrical Apparatus for Potentially Explosive

Atmosphere [EEx(d)]

FCI 70-2 2006 Control Valve Seat Leakage

IEC 534-8-3 1995 Control Valve Aerodynamic Noise Prediction Method

IEC 60079 2006 Electrical apparatus to explosive gas atmosphere.

IEC 60529 2004 Classification of degrees of protection provided by

Enclosures (IP codes).

IEC 60801 1991 Electromagnetic compatibility of Industrial-Process

management and control equipment

ISA S20.50 1998 Specification Forms for Process Measurement and Control

Instruments, Primary Elements and Control Valves

ISA S75.01 2002 Flow Equations for Sizing Control Valves

ISA S75.05 1997 Control Valve Terminology

ISA S75.11 1997 Inherent Flow Characteristic and Rangeability of Control

Valves

ISA SP75.17 1995 Control Valve Aerodynamic Noise Prediction

ISA RP75.23 1995 Considerations for Evaluating Control Valve Cavitation

MSS-SP-61 2003 Pressure Testing of Steel Valves

2.2.2 National Codes

IBR 2008 Indian Boiler Regulations

IS-2148 2004 Flame proof enclosures for electric apparatus, etc:

IS-1271 1985 Methods for determining thermal classification of electric

insulation.

2.2.3 IBR Certification

For valves described ‘IBR’, valves shall be in accordance with the latest IBR including the

requirements specified in the specifications. Valves coming under ‘IBR’ shall each be individually

accompanied by IBR certificate original in Form III-C duly approved by IBR authority / local

authority empowered by Central Boiler Board of India. Photocopy of originals certificate duly

attested by the local boiler inspector where the bidder/manufacturer is located is the minimum

requirement for acceptance.






2.3 Deviations to Specification

2.3.1 The Bidder shall provide an item wise list of any deviations to this specification. These shall be

listed on the compliance sheet with seal & duly signed by authorised signatory & shall be submitted

along with offer.

2.3.2 Where a conflict in standards occurs then the Bidder shall seek a clarification ruling from the

Owner. Where a deviation from the standard is required, then the Bidder shall make a formal

request with full supporting information.

2.3.3 Only those deviations that are agreed between the Owner and the Bidder will be incorporated into

the requisition at the time of order.

2.4 Conflicting Requirements

In case of conflict between documents relating to the enquiry or purchase order, the following

priority of documents shall apply:

First priority : Data Sheets.

Second priority : This specification.

Third priority : International Standards.

Note: Should any conflict arise either before or after order placement the Bidder shall immediately

inform the Owner / Consultant for technical resolution of the conflict.

2.5 Associated Project Documentation.

Specifically applicable codes are found at the beginning of each section of the Project specifications

relevant to Instrumentation and Automation

254625-300-DB-GEN-006 Project Design Basis

254625-300-VL-INT-002 Approved Vendor List

254625-300-SP-PIP-002 Piping Specification Index

254625-300-SP-PIP-003 Specifications for Painting

254625-300-SP-PIP-018

(Globe)

Piping Valve specifications

254625-300-SP-INT-004 Specifications for Motor Operated Valves

254625-300-DS-INT-024 Data sheet for Motor Operated Pressure Control Valves & Tag

List

254625-300-DS-INT-025 Data sheet for Motor Operated Temperature Control Valves &

Tag List

2.6 Abbreviations & Terminology

CV Control Valve

ESDV Emergency Shutdown valve

FC Fail Safe Close

FO Fail Safe Open

HFHSD High Flash High Speed Diesel

IEC International Electro technical Commission

IS Intrinsic Safety

ISA Instruments Society of America

JB Junction Box

LSHS Low Sulphur heavy stock

LVFO Low Viscosity Furnace Oil

PCV Pressure Control valve






SOV Solenoid Operated Valve

TCV Temperature Control Valve.

VDC Volts direct current

VFD Variable frequency drive.

CCOE Chief Controller Of Explosives

CMRI Central Mining Research Institute

TSV Thermal Safety Valve

3 PLANT LOCATION

For plant location and environment condition refer to Project Design Basis document no. 254625-

300-DB-GEN-006

4 Hazardous Area Classification and Protection

4.1 Instruments located in hazardous area shall be certified to meet or exceed the electrical hazardous

area defined by Area classification

4.2 Motor operated actuator & accessories used shall be flame proof and all limit switches shall be

intrinsically safe certified with volt free contact and suitable for hazardous area of Zone 1, Group

IIA/IIB, T3 applications. Additionally all valve associated instruments shall be weatherproof to

IP65. Instruments certified for use in the specified hazardous area classification shall be recognized

by authority like FM, CENELEC, PTB, BASSEFA, ATEX , CCOE etc.

5 Utilities Specification

Electric Supply of 415 V AC, 50 Hz, 3 Phase OR 220 V AC 50 Hz, 1Phase power supply shall be

provided by others.

6 SCOPE OF SUPPLY

This specification covers the minimum requirements for design, manufacture, testing and supply of

motor operated control valves as a complete assembly of valve & modulating linear actuator unit

with all accessories as per this specifications and data sheets. All interconnecting valve accessories

between the valve, actuator, gear, hand wheel, positioner, and position transmitter etc. are in

bidder’s scope.

7 CONTROL VALVE

7.1 Design & Construction

7.1.1 Control valves shall in general of Globe type with Flanged ends. It shall be pre-assembled with

electric motor operated modulating type linear actuators, position indicators & transmitter etc. as

required. Motorised Actuators shall be Electric power driven & type of power available is as

specified in Utilities Specification.

7.1.2 The minimum control valve body size shall be 1”. In all cases, the control valve nominal body size

shall not exceed the nominal line size.

7.1.3 All control valves shall have removable seats, trim, inner valve parts, enclosed springs and position

indicators.

7.1.4 The valve shall be suitable for installation in horizontal or vertical lines. The flow direction shall be

clearly stamped or cast marked on the valve body.






7.1.5 Control valve bodies with reduced trims shall be considered for applications with the following

conditions:

– Pressure drop is excess

– Gas/vapor outlet velocity is excess

– High noise exceeding 85 dBA

– Choked flow

– Flashing exceeding 5% weight of liquid being vaporized

– Erosive fluids

7.1.6 Each control valve shall be sized and selected to provide reliable operation and control at the

specified operating and design conditions. Control valve sizing shall generally be based on ISA

S75.01, “Flow Equations for Sizing Control Valves”.

7.1.7 In general, the maximum flow shall be achieved with 90% opening (not to exceed 90%), the normal

flow achieved with 40-75% opening and minimum flow achieved with 20% opening.

7.1.8 The selected control valve trim capacity (Cv selected) should meet the following:

a) An equal percentage trim shall operate below 95% travel at maximum flow.

b) A linear trim and quick opening trim shall operate below 90% travel at maximum flow.

c) The Cv capacity required to meet above criteria is referred to as “Cv required”. The actual Cv

capacity of the valve is referred to as the “Cv selected”. Specific applications may require an

over-sized Cv capacity, which shall be specified by the Purchaser.

7.1.9 Bidder may deviate from the ISA formulas provided that the reason is detailed in the technical

quotation.

7.1.10 Bidder shall select and size the control valve as well as actuator assembly and accurately evaluate

the minimum trim performance requirements.

7.1.11 Capacity calculations for all operating conditions shall be provided. The calculation basis and

results shall be shown for manual or computer calculations. For valves mounted between pipe

reducers or other pipe fittings, the calculated valve capacity shall be corrected for a decrease in

valve capacity conforming to ISA S75.01. The piping geometry factors FP, control valve correction

factor etc. shall be specified by the Bidder.

7.1.12 Raised face (RF) flanged connections shall be used and shall comply with ASME B16.5.

7.1.13 Unless otherwise noted, face-to-face dimensions of flanged valves should comply with ASME

B16.10. Bidder to advise face-to-face dimensions proposed.

7.1.14 Bidder shall select the control valve flow characteristic to meet the rangeability requirements as

defined in data sheet.

7.1.15 Bidder shall provide a control valve that eliminates cavitation, choked flow, or flashing conditions

in the control valves.

7.1.16 The Actuator for the control valves in general shall be of Electric Motor Operated, Modulating

type, Linear Actuators shall be working on 2 wire control system same as Motor Operated Quarter

Turn On/Off Valves & shall work on same network.






7.1.17 The total maximum inaccuracy of the valve travel position due to any limitation (i.e., repeatability,

deadband, resolution, hysteresis, etc.) shall be less than 2.0%.

7.1.18 Each control valve shall be provided with a local valve position indicator. The indication pointer

shall be directly connected to the stem or shaft. The valve position shall be indicated on a reversible

scale with clearly graduated markings at 25% valve opening position intervals and the words OPEN

and CLOSED at the valve travel limits. It shall also have position transmitter for remote monitoring

of % opening of valve.

7.2 Seat Leakage

7.2.1 Seat leakage classification shall be in accordance with FCI 70-2 or MSS-SP-61. The leakage class

shall be determined by the service application. Soft seated valves shall not be applied in services

with design temperature conditions over 230°C (450°F) or in flashing liquid services.

7.2.2 The maximum shut-off differential pressure shall always be calculated and specified for the

selected control valve. For all metal-to-metal shut-off applications equal to or exceeding FCI 70-2

Class IV requirements, actuator load calculations shall be provided. Calculations are required to

show the minimum load to be applied to the plug-seat arrangement for meeting the required shut-

off specifications.

7.3 Minimum Rangeability

7.3.1 The installed rangeability (actual available rangeability) of each control valve in the process system

shall meet all flow conditions specified. The specified minimum flow condition shall be fully

controllable.

7.3.2 Typical rangeability of valves shall be 30:1, unless otherwise specified.

7.4 Packing & Gaskets

7.4.1 Control valves shall normally be furnished with Teflon packing, generally for operating

temperatures between minus 40° C to 200° C.

7.4.2 Packing boxes shall be flanged bolted to the bonnet. Valve packing shall be spring loaded and

adjustable.

7.4.3 Body gaskets for temperatures below 230°C shall be PTFE or equal. Over 230°C, a spiral-wound

gasket, grafoil-type gasket, or equal, shall be used. In all cases, valve gaskets for body/bonnet joints

or bottom flange joints shall be metal seal or spiral wound stainless steel with a non-asbestos or

Teflon filler suitable for the operating and design conditions.

7.5 Bonnets

7.5.1 A standard bonnet shall be specified for temperatures of 30°C to 230°C. Control valves shall be

furnished with bonnet cooling extension if required by the operating process temperatures, packing

type combination, generally above 250°C or supplier’s standard which ever is lower.






7.6 Materials

7.6.1 Control valve body materials shall meet, or exceed, the requirements of the application. Body and

trim materials shall meet the temperature requirements. Trim materials shall be selected to

withstand corrosion, erosion and wear under severe service conditions.

7.6.2 Control valve body and trim material of construction shall be selected based on piping material

specifications. For normal application, as a minimum, trim material shall be SS 316. And for steam,

high pressure/temperature, erosive applications fully stellited trim shall be used as per application

requirement.

7.6.3 The entire closure member surface exposed to the flow path, including guiding area shall be

Stellited SS316. Hard facing of seating and guide area only is not acceptable.

7.6.4 The seat ring shall be SS316 with Stellite sheath on entire seating and surface area exposed to flow

path. Solid Stellite is an acceptable alternative.

7.6.5 The seat ring retainer, which is not exposed to high fluid velocities may be of stainless steel

compatible with the fluid. However, a seat ring retainer in the outlet stream of the valve shall be

SS316 with Stellite facing on all exposed surfaces.

7.6.6 The guide bushing shall be Solid Stellite or similar hardened material suitable for low temperatures.

7.6.7 In all cases exit baffle plates can be used, in order to prevent cavitations within the body chamber,

and to cater for high pressure drops.

7.7 Noise

7.7.1 The maximum noise level emission from a control valve installation shall not exceed 85 dBA, at

one meter from valve in all directions, for any specified operating condition. Special trims shall be

used, if necessary, to ensure that noise level does not exceed above limit.

7.7.2 Bidder shall submit detailed noise calculations with the proposal in accordance with methodology

outlined in ISA SP75.17 and IEC 534-8-3 guidelines. Bidder shall guarantee control valves

supplied meet the above requirements.

7.8 Trim Design

7.8.1 Valve trim shall be of the quick-change type for ease of maintenance. No internal components shall

be screwed or welded into the valve bodies or bonnets. Trim shall be designed to provide equal

pressurization around the plug in order to minimize vibration and prevent any potential for binding.

Bidder shall select control valve trim design that meets the requirements of this Specification.

7.8.2 Valve flow characteristics shall be as specified on datasheet.

7.8.3 Unbalanced, single ported globe valves shall be closure member guided. Balanced, single ported

globe valves shall be cage guided.

7.9 Accessories

7.9.1 Valve Positioner

7.9.1.1 All control valves shall be furnished with electric positioners.






7.9.1.2 Separate ½” NPT (F) cable entry to be provided for positioner feedback.

8. MOTOR OPERATED CONTROL VALVE SYSTEM

8.1 General

8.1.1 Motor Operated Control Valve system shall be complete in all respect to execute modulating

controls and provide data on operation variables for the actuator to ensure efficient operation of the

Motor operated control valves.

8.1.2 Actuator shall be suitable for 2 wire control system. Only Open Protocols such as MODBUS RTU

is acceptable. It should be possible to integrate the Actuator with MODBUS RTU protocol with

Intermediate Master Station. The Master Station shall then be interfaced with TAS PLC system.

Actuator Communication system & TAS PLC shall have seamless interface & shall be redundant.

8.1.3 The paramount reason for MODUS RTU open protocol is to have seamless interface

communication with various makes of actuators on same loop with out any additional hardware &

software. Valve bidders & Actuator vendors shall guarantee the performance of MOV & its

MODBUS interface with TAS PLC & with other Actuated valves on same multi drop cabling loop

for faster communication.

8.1.4 The system shall basically consist of a central control unit communicating to various field interface

modules (located inside individual Motor operated Valve actuator housing) over a communication

network.

8.1.5 The control system shall be capable of controlling a minimum of 200 field devices over a single or

multiple network meeting the performance requirement specified here under. Bidder shall refer the

instrument layout drawing no. 254625-300-INT-A0-5307 Rev A. Some of the actuated valves are

located over a distance more than the permissible multi drop loop length for MODBUS. A suitable

MODBUS Interface repeater installed in flame proof enclosure shall be supplied.

8.1.6 The control valve control system shall support the linear / modulating control valves. It shall also

support the quarter turn motor operated on/off valves.

8.1.7 HVs, ESDVs & CVs may be connected on same redundant 2 wire control loop.

8.1.8 Protocols other than MODBUS RTU & proprietary Communication Protocols for Actuators are not

acceptable.

8.2 Field Control Unit

8.2.1 The field control unit shall be integral to actuator and shall be powered from the actuator power

supply. No separate power supply shall be provided for operation of field unit

8.2.2 The field control unit shall be able to execute the following operational commands

• Modulating linear control w.r.t PID output from PLC controller.

• Fully Open/Close the valve.

• Inching control

• Emergency shut down (Hardwired contacts from TAS PLC shall be provided for ESD

actuation)






• Emergency shut down (ESD) signal shall over-ride any other signal command including

motor winding temperature bypass.

• 2 wire communication with TAS PLC (through master control station as applicable)

8.2.3 Following signals and alarms shall be transferred by field control unit over the network:

• Continuous valve position

• Valve opening

• Valve closing

• Valve % open

• Valve % close

• Valve stopped

• Local push button depressed

• L/R in remote

• Torque switch tripped

• Loss of main power

• Loss of control power

In addition to above the following diagnostic alarms shall also be transferred:

• Actuator fault

• Field unit fault

• Loss of phase

• Thermostat tripped

• Torque switch tripped

• Valve jammed

• Contactor fails to energize

8.2.4 Actuator/ field control station shall accept hardwired contacts for emergency operation or

emergency shutdown operation of the valve in addition to serial two wire signal.

8.3 Master Station

8.3.1 Supply of Microprocessor based Master control station provided to control and monitor all motor

operated control valve actuators is in the scope of this tender. Master station shall be housed in

panel located in instrument equipment adjacent to main control room and interfaced with plant PLC

through redundant communication link. Plant PLC and master station will operate on master/slave

mode. Master station shall receive commands like open/close/stop from the PLC and shall operate

the control valves. All information about all actuators shall be available at PLC through master

station.

8.3.2 Master Control Station (MCS) unit shall be complete with a dedicated keyboard and a display unit.

It shall be possible to operate the actuators and configure the network devices from the

keyboard/display unit. Protection shall be provided in the MCS for selecting configuration mode.

8.3.3 Master station/Central control unit shall have the following minimum features: -

8.3.3.1 Each Mater station/Central control unit shall have capacity to connect and control

minimum 240 motor actuated valves. It shall have provision for extending the no of

nodes in case required in future.

8.3.3.2 It shall have REDUNDANCY in communication, processor and power supply and there

shall be bump less transfer in case of failure of any one of the above. Master

station/Central control unit shall be with dual redundant configuration in such a way that

failure of one processor unit shall automatically transfer the control to the redundant unit.






8.3.3.3 The switch over time shall be of the order of 100 msec. The output shall hold to the last

state during switch over.

8.3.3.4 The system software shall include all software necessary for operation, displays and

configuration of the complete system, along with software for communication with TAS

PLC. Software shall also be provided for the detailed diagnostics within the system

including in the master control unit and in the network. The system shall also be capable

to display all diagnostic alarms including those for field control units, network and of

central control unit. Diagnostics shall also identify and display the exact location of

network fault. It shall have it's dedicated self diagnostic features to find out faults like

cable fault (for cable open and cable short or grounded), actuator communication is not

reached and all actuator faults and alarms, etc) and it shall have real time clock to

monitor alarm events/data/faults.

8.3.3.5 It shall have facilities to set parameters like baud rate, address, skipping of few actuators

during maintenance, etc.

8.3.3.6 It shall have capacity to receive at least 25 digital signals and 5 analog signals through

communication link from each valve actuator.

8.3.3.7 The system configuration shall be stored in the retentive memory.

8.3.3.8 It shall be possible to include or delete any of the MOV, control valve from the system

from Master Control Station.

8.3.3.9 It shall have capacity to store and display the following events. The memory size shall be

20% extra for future expansion.

a) Valve actuator and control signals and its operation status.

b) Number of operations of each MOV'S from its normal state.

c) Valve and operator position log

d) Actuator control status log

e) Statistics

f) Historical data/ events

g) Actuator failure information.

8.3.4 The master station/central control unit shall be connected to each field mounted valve actuator

through redundant communication interface link and back to master station in ring topology. It shall

perform tasks of data collecting from each actuator, storing the data's and receiving the command

signals from PLC and send the same to respective actuators for it's operation. It shall be possible to

operate the valve from the master station. When MOV'S are operated from master station, the

command signals form the Plant PLC are ignored and only status signals shall be sent to PLC.

Contractor shall include necessary software and hardware to establish communication link. If any

special programming tool is required the same shall be supplied.

8.3.5 Master station and field units shall be protected against lightening by the provision of transient

suppressor devices on all 2 wire connection ports at 1.5 KV at 1 mS. Opto isolation shall be used

within the field units and Master station for enhanced noise protection.

8.3.6 The cabling, testing, commissioning for MOV’s & Electric Motor Operated Control Valves are

included in the scope of the TAS contractor. The MOV & control valve supplier shall assist the TAS






contractor in integration of these valves with TAS. Valve bidder shall have co-ordination with TAS

contractor for seamless integration of MOV’s with TAS.

8.4 Network Requirements

8.4.1 All field units shall be connected to master control unit using 2 wire network, consisting of 1 twisted

pair, shielded, 1.5 mm2 Cu conductor cable being provided by the TAS Contractor. Valve Contractor

shall advise the suitability of this cable and inform system performance parameters accordingly, along

with the bid.

8.4.2 The network communication protocol shall be Full Duplex type and shall incorporate a robust

mechanism viz. CRC etc. to identify proper data transfer.

8.4.3 The network shall be designed so as to allow uninterrupted data transfer even in case of network

failure (discontinuity in cable failure of one field module etc.) at a single point.

8.4.4 Proper isolation shall be provided for all the network connectors in order to avoid electrical interface

problems.

8.5 Performance Requirements

8.5.1 The system shall be designed and engineered so as to provide reliable two way communication

between the TAS, the Master station/Central control station and the Field modules The

communication speed of the network should be selected so as to maintain data integrity even in case

of the worst case of data transfer conditions. In any case the Maximum data transfer time for any

command from central control unit to field station and vice versa shall not exceed 5 seconds for the

network length and no of devices.

8.6 Operational Requirements

8.6.1 All MOVs shall have the provision for wiring the two wire network from Master control station and

additionally MOV’s tagged as ESDVs shall be capable of accepting hardwired ESD inputs directly

from TAS PLC. Normal operational commands, status indications and diagnostic alarms shall be

routed to Master Stations over a two-wire system. Whereas ESD inputs shall override any other

command and close the MOV on its actuation.

8.7 Actuators 8.7.1 Actuators which are self-contained package units shall be used for electrical operation of control

valves. Each actuator shall comprise a three-phase electric motor/single phase/DC motor, reduction

gearing, reversing contactor starter complete with local controls, turns and torque limitation facilities,

electronic logic controls and monitoring facilities.

8.7.2 Actuators shall be suitable for use on 415 volt 3 phase OR 220 volt 1 phase 50 Hz power OR 24

VDC. If required the actuator motor and starter shall be provided with heaters to prevent

condensation.

8.7.3 All actuator shall be O-ring sealed, watertight and dustproof to IP65 and shall at the same time have

an inner watertight and dustproof O-ring seal between the terminal compartment and the internal

electrical elements of the actuator, fully protecting the control mechanism, motor and all other

internal electrical elements of the actuator from ingress of moisture and dust when the terminal cover

is removed on site for cabling.






8.7.4 Enclosure shall be rated explosion proof Ex ‘d’ and suitable for installation in Zone 1 IIA/IIB,

Temperature Class T3 electrical area classification. The actuator shall be sized to guarantee valve

closure and provide sufficient thrust to position and fully stroke the valve against the maximum

differential pressure that may develop under the specified process and/or start-up conditions.

Particular attention shall be paid to unbalanced dynamic forces on the valve plug. For actuator sizing,

the shutoff differential shall be considered at full differential pressure. The full differential pressure

for actuator sizing shall be assumed as the maximum upstream pressure with the valve fully closed

and downstream pressure as atmospheric.

8.7.5 The safety margin of motor power available for seating and unseating the valve shall be sufficient to

ensure torque switch trip at maximum valve torque with the supply voltage at 10% below nominal.

The operating speed shall be such as to give valve closing and opening rate at approximately 10-12

inches per minute.

8.7.6 The actuator shall be available with mounting base and output drive couplings conforming to ISO

5210.

8.7.7 A lockable hand/auto lever shall be provided to engage handwheel operation. Energization of the

motor shall automatically re-engage power operation. Two selectors shall be provided on the actuator,

one for Local/Stop/Remote selection, and with padlockable for each position and the other for Open,

Close and Stop Commands.

8.7.8 Electronic “latching” shall be provided for the torque sensing system to inhibit torque off during

unseating or during starting in mid travel against high inertia loads. A jammed valve protection circuit

shall de-energize the motor after a few seconds, if no movement occurs after receipt of a signal to

open or close.

8.7.9 A local display shall give continuous indication of the actuator position

8.7.10 A separately sealed compartment containing segregated power and control terminals shall be

provided. Earthing terminals shall be provided at the external of MOV. The common connection of

the contactor coils at the transformer shall be grounded so that the contactors drop out in the event of

a leakage to ground. The primary winding shall be separated from the secondary by a grounded

screen. The secondary output shall be protected by a fuse of an easily replaceable cartridge type.

8.7.11 An instruction handbook and wiring diagram shall be enclosed with each actuator. A durable terminal

identification card shall be provided attached to the inside of the terminal box cover indicating the

following:

♦ Serial Number

♦ External Voltage values

♦ Wiring diagram number

♦ Terminal Layout

♦ Valve Actuator Interface

8.8 Electrical Position Transmitter

If called in the data sheets a suitable 4-20Ma position transmitter shall be provided -

8.8.1. The Position Transmitter provided shall be 2-wire R-I converter to give an output of 4-20 mA. Input

power supply to transmitter card shall be 24V, DC.

8.8.2. Accuracy of Position Transmitter card shall be less than 1%.






8.8.3. Position Transmitter card shall be suitable for operating in a temperature range of –200 C to +800 C.

8.8.4. Position Transmitter card shall be epoxy filled with minimum IP 66 protection class. Bare PCB card

is not acceptable.

8.9 Motors 8.9.1 The actuator motor shall be three-phase, Class F insulated, squirrel cage motor of special high torque

low inertia design, 15 minute rated at 33% of actuator output rated torque giving a temperature rise

not exceeding that permitted for Class B insulation at standard voltage of 415 volts, 50 Hz. Burn-out

protection by embedded thermostat shall be provided. Motor shall be capable of 60 starts per hour.

Motor shall be certified Ex “d” and be suitable for operating in a Zone 1 IIA/IIB Temperature Class

T3 electrical area classification.

8.9.2 The integral power module in the motor shall incorporate a mechanically and electrically interlocked

reversing contactor starter, a control supply transformer fed from two phases of the incoming power

supply, an automatic phase rotation correction circuit to ensure that the phase motor is always

presented with a correct phase of the power supply and a single phase protector which prevents

energizing the contactors if one or more phase of the power supply is lost.

8.10 Testing

For MOVs the following tests shall be provided prior to shipping:

♦ Actuator operation, Cycle (open-close) each valve with its actuator at least five times, for proper

actuator operation. Verify that valve position coincides with position indicators.

♦ Opening -closing position

♦ Actuator output speed

♦ Current and torque at maximum torque setting

♦ Hydraulic test of valve, at test pressure as per API 6D

♦ Operational torque test as per C.4 of API 6D. The maximum measured torque shall be less than 75

% of the design torque specified by the valve manufacturer for actuator sizing.

♦ FAT and SAT for the system

♦ Individual test certificates shall be provided for each MOV. The test certificate should contain

details of specification such as gear ratios for both manual and automatic drive, closing direction,

wiring diagram code number etc.

8.11 Site Service / Site Visits by Experts.

HVs, ESDVs & CVs Software Integration with TAS PLC:

Valve Vendor shall depute expert service engineer/engineers to site

- To demonstrate & establish successful communication interface with valves & up to TAS

PLC system. Parameter settings for establishing the communication between TAS PLC

system, Master Station, Field Control Units & HV’s, ESDVs & CVS.

- Close co-ordination with TAS contractor for complete integrated stage wise testing of the

system & stroking of the valves & complete testing, stroking after successful completion of

stage wise testing.

- Fine tuning of the integrated system for optimal performance of valves & TAS.

- Details of all parameter settings & documents to TAS contractor for incorporating these

details in TAS manuals.

- In case of problems with the valves stroking/functioning during commissioning and warranty

period, shall depute his service expert to site for rectification of problems of actuated valves.






Manufacturer/bidder shall repair or replace the actuated valves/accessories & demonstrate its

operation to Engineer In-charge/Client to their satisfaction.

Tools, tackles, consumable & manpower etc. required at site for this purpose shall be arranged by

manufacturer/bidder. All expenses for site services shall be borne by manufacturer/bidder.

9 IDENTIFICATION

9.1 Each valve and actuator shall be provided with an identification plate, with all data clearly and

indelibly stamped on a stainless steel plate, permanently attached to the instrument by means of SS

rivets. In addition, a stainless steel tag shall be provided that is permanently attached to the

valve/actuator by a chain or wire.

9.2 The following information shall be provided as a minimum on nameplate :

• Purchaser’s Tag Number.

• Manufacturer’s Name or Trademark

• Manufacturer’s Model Number.

• Manufacturer’s Serial Number.

• Body size and rating.

• Fail Safe Condition

• Cv

• Actuator Model

• Spring Range

• Power Supply

• Leakage Class

• Travel/stroke

• Operating signal range

10 INSPECTION AND TESTING

The complete valve and actuator assembly together with its accessories shall be inspected and

tested by the Owner/MMCI/ TPI (Third Party Inspector) prior to dispatch unless otherwise advised.

Bidder shall inform at least 6 weeks in advance for the inspection. Each control valves shall be

tested in the following manner:

10.1 Hydrotest

Hydrostatic test shall be according to applicable code ANSI B16.34. Each control valve body shall

be subjected to hydrostatic test at 1.5 times the test pressure as per ANSI rating, all valve bodies

covered under IBR, shall be tested as per IBR regulation. There shall not be any visible leakage

during this test.

10.2 Seat leakage test

The seat leakage test shall be in accordance with ANSI B16.104 with the acceptance criteria for the

specified shut-off class.

10.3 Functional Test






10.3.1. Complete valve operation shall be checked by simulating the signal to valve positioner and

checking for correct calibration. Signals shall be simulated in the sequence of 0 %, 25%, 50%, 75%,

100%, 75%, 50%, 25%, 0%.

10.3.2. The hysteresis shall also be measured which consist of measuring the valve stem in response to the

above sequence of input signals.

10.3.3. For PTFE-based packing, the hysteresis shall not exceed 1.0% of maximum valve stroke.

10.3.4. The dead band is expressed as a percentage of the input span and shall be measured at 5%, 50%,

and 95% of the input span. For PTFE-based packing, the maximum dead band found shall not

exceed 2% of rated input signal.

10.3.5. For packing other than PTFE, the maximum hysteresis and dead band shall be quoted by the

Manufacturer for the approval of the Owner/Consultant.

10.4 Test & Test Certificate

10.4.1. Unless otherwise specified, purchaser reserves the right to test and inspect all the item at the

Bidder’s works.

10.4.2. Bidder shall submit following test certificates and test reports

10.4.2.1 Material test certificates with detailed chemical analysis from the foundry for each

casting.

10.4.2.2 Certificate of radiography / X-ray for valve casting.

10.4.2.3 IBR certificate in form III C for all valves covered under IBR certification

10.4.2.4 Test certificate for each valve giving detail of hydrostatic tests, calibration/stroke checks,

seat leakage tests, valve characteristics, testing of accessories etc.

10.4.2.5 Factory test certificate and material certificate for actuator and its accessories shall be

submitted.

10.4.3. Valve Complete With Actuator

Components installed within the assembly shall be type tested in accordance with the applicable

IEC publications (e.g. IEC 947). Certificates, obtained from the Manufacturers of the components,

shall be made available at the request of the Owner/Purchaser.

11 SPARES AND SPECIAL TOOLS

The supply of spares for start-up and commissioning shall be supplied. A list of recommended

spares for two years operation and maintenance shall be attached with offer. Bidder shall supply a

set of any special tools required for installation, commissioning, operation and maintenance of the

control valve offered. A list of special tools shall be supplied along with the offer.

12 BIDDER DOCUMENTATION

12.1 Information to be supplied with offer

The Bidder shall provide the Owner/consultant with the following information as a minimum along

with the tender. These documents shall include, but not be limited to the following:






• Filled up Data Sheet, complete with MOC details of Valve and Actuator, manufacturer &

model no for each valve assembly duly signed and stamped.

• Control valve sizing.

• Valve and Actuator General Arrangement Drawing showing main components, main

dimensions, weights, part lists and material.

• Tag / size wise power consumption.

• List of recommended spare parts for start up and commissioning.

• List of recommended spare parts for two years of operation and maintenance

• Special tools, if required

Any other information considered necessary by the Bidder to show conformity to this Specification

shall be provided.

12.2 Information to be supplied after LOI/PO

Vendor shall provide six sets of the following documents

• General arrangement of completely assembled valve showing main components, main

dimensions, weights, part lists and material for approval (after 2 weeks of LOI / PO).

• Filled up Data Sheet complete with MOC details of Valve and Actuator, manufacturer &

model no for each valve assembly (after 2 weeks of LOI / PO).

• Valve positioner details & wiring requirements.

• Control valve sizing for approval (after 2 weeks of LOI / PO).

• Catalogues (after 2 weeks of LOI / PO).

• Bidder’s hydrostatic test report for each control valve.

• Bidder’s seat leakage test report for each control valve.

• Bidder’s stroke performance test report for each control valve.

• Certified Material Test Reports for each control valve.

12.3 Final Documentation

Vendor shall provide as a minimum the following documents (8 hard copies + 4 soft copies)

• General arrangement of completely assembled valve showing main components, main

dimensions, weights, part lists and material for approval.

• Filled up Data Sheet of Valve and Actuator, manufacturer & model no for each valve

assembly.

• Control valve sizing.

• Technical data / catalogues for Vendor supplied items & bought-out items.

• Installation requirements

• Calibration certificate

• All documents mentioned in certification

• Hazardous area classification certificate

• Inspection clearance certificate (Owner /consultant / Third Party Inspector)

• O & M Manuals and drawings

13 TRANSPORTATION AND STORAGE

13.1 Equipment shall be protected to safeguard against all adverse environment conditions that may be

encountered during shipment, storage and installation.

13.2 All exposed unpainted surfaces shall be coated with preservatives or wrapped.






13.3 Cable entries & process line connections shall be plugged or capped.

13.4 Valves that shall be blinded off using bolted metal covers with gaskets and sealed with tape. Valve

internals shall be protected with approved preservatives.

13.5 Boxes containing electronic components shall be sealed with tape or polyethylene sheeting after the

installation of silica gel bags. Positioner fronts shall be fitted with protective plywood sheets.

13.6 The valves shall not be dismantled for shipment.

13.7 Separate, loose, and spare parts shall be completely boxed. Pieces of equipment and spare parts

shall be identified by item number and service, marked with Bidder's order number, tag number,

and weight, both inside and outside of each individual package or container. A bill of material shall

be enclosed in each package or container of parts.

13.8 One complete set of the installation, operation, and maintenance instructions shall be packed in the

boxes or crates with equipment. Packing list with all details shall be pasted on each crate or box.

14 GUARANTEE

Any acceptance or release of the completed valve assembly following an inspection or test activity

shall in no way relieve the Bidder of his responsibility to provide guarantees as to the suitability of

the materials, workmanship and performance of the valves/actuators in accordance with this

Specification. Bidder shall supply a certificate of compliance with the applicable descriptions, the

data sheet and the test results (including stroking times), for all valves/actuators and accessories as

per the order.

15 SITE SERVICES

15.1 Motor Operated Control Valve’s Software Integration with TAS PLC: Valve Vendor shall depute

expert service engineer/engineers to site

15.1.1 To demonstrate & establish successful communication interface with valves & up to TAS

PLC system. Parameter settings for establishing the communication between TAS PLC

system, Master Station, Field Control Units & HV’s, ESDVs & CVs.

15.1.2 Close co-ordination with TAS contractor for complete integrated stage wise calibration

testing of the system & stroking of the valves & complete testing, stroking after

successful completion of stage wise testing.

15.1.3 Fine tuning of the integrated system for optimal performance of valves & TAS.

15.1.4 Details of all parameter settings & documents to TAS contractor for incorporating these

details in TAS manuals.

15.1.5 In case of problems with the valves calibration/stroking/functioning during

commissioning and warranty period, shall depute his service expert to site for

rectification of problems of motor operated valves. Manufacturer/bidder shall repair or

replace the motor operated valves/accessories & demonstrate its operation to Engineer In-

charge/Client to their satisfaction.

15.1.6 Tools, tackles, consumable & manpower etc. required at site for this purpose shall be

arranged by manufacturer/bidder. All expenses for site services shall be borne by

manufacturer/bidder.