Design Division Engineering Services 11 - High, Mumbai ISO 9001: 2000

Functional Specifications SUBSEA INTERVENTION VALVE ACTUATOR

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FUNCTIONAL SPECIFICATION FOR SUBSEA INTERVENTION VALVE ACTUATORS

PREPARED / REVISED BY

REVIEWED BY

APPROVED BY

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DATE

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Design Division Engineering Services 11 - High, Mumbai ISO 9001: 2000

Functional Specifications SUBSEA INTERVENTION VALVE ACTUATOR

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CONTENTS

Clause No. 1.0 2.0 3.0

ITEM Scope of This Document Scope of Supply Sub sea Intervention Valve Actuator 3.1 3.2 3.3 Design & Construction Material Manufactures qualification

Page No. 3 3 4 4 7 7 7 7 8 8 8 9 9 10 10 11

Miscellaneous 4.1 4.2 4.3 4.0 4.4 4.5 4.6 4.7 4.8 4.9 Inspection & Testing Non destructive testing requirements Valve / Actuator assembly test Extent of inspection & testing Tests certificate report Painting & Marking Spares & accessories Documentation Warranty

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Design Division Engineering Services 11 - High, Mumbai ISO 9001: 2000

Functional Specifications SUBSEA INTERVENTION VALVE ACTUATOR

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1.0

SCOPE OF THIS DOCUMENT: This specification covers the minimum requirements for design, manufacture, inspection and testing of subsea intervention valve actuators suitable for installation on ball valves in submarine pipeline systems handling hydrocarbons in liquid or gaseous phase and injection Water. This specification shall be read in conjunction with Functional specification for sub sea Ball valve, Hydraulic Power Unit (HPU), Umbilical. HPU cum- Control panel and umbilical sizing shall be the responsibility of the actuator vendor. Subsea intervention valve system consisting of subsea valve, subsea actuator, HPU-cum-Control panel etc. shall be supplied with single point responsibility functional specification describes the essential design considerations for the selection of subsea intervention valve actuator for the intended service.

2.0 2.1 2.2

SCOPE OF SUPPLY: The quantity to be supplied and installed shall be as per the requirements indicated in the Basic Bid Work, Design Criteria and the P & IDs. The vendor shall be responsible for the selection of the subsea intervention valve actuators suitable for its intended application, its procurement, tagging, packing, testing & calibration, preparation for shipment, along with accessories, spares, and assistance where required for its installation & commissioning at site. This FS shall be read in conjunction with: Instrumentation Design Criteria Basic Bid Work Project P & IDs Process Design Criteria Electrical Design Criteria Piping Design Criteria Mechanical Design Criteria Environmental condition of the project

2.3

Reference has been made in this specification to the latest edition, enforce at the time of issue of enquiry of the following applicable Codes, Standards and Specifications. ASME B 31.3 Process Piping

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Design Division Engineering Services 11 - High, Mumbai ISO 9001: 2000

Functional Specifications SUBSEA INTERVENTION VALVE ACTUATOR

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ASME B 16.5

Steel Pipe Flanges and Flanged Fittings

ASME B 16.47 Large Diameter Steel Flanges MSS-SP-44 SSPC-VIS-1 DNV-1981 3.0 3.1 3.1.1 Steel Pipeline Flanges Steel Structures Painting Council Visual Standard Det Norske Veritas Rules for submarine system

SUBSEA INTERVENTION VALVE ACTUATORS DESIGN AND CONSTRUCTION Actuators for operating subsea ball valves shall be designed for permanent subsea Installation in water depth and service conditions indicated in Actuator Data Sheet /process data sheet. Actuator design shall be of scotch-yoke /rotary vane / helical spline type mechanism. The actuator design shall maintain the selected valve position fully open or fully closed and shall ensure the FAIL SAFE (denergize to close in case of subsea intervention valves) condition of the sub-sea valve as per the process requirement. Requirement of Fail safe or fail locked shall be described in P&ID/Process design criteria. Actuators shall be designed for operation by hydraulic fluid at pressures ranging from 70 kg/Cm2 (g) normal to 105 Kg/Cm2 (g) maximum from Hydraulic Power Unit (HPU) via Control Umbilical. In addition, actuators shall also be designed for operation by hand held Nitrogen Cylinders by divers. HPU shall be stationed on the Platform and shall be stationary unless otherwise specified. Actuators shall be designed for an operational life of 25 years, unless specified otherwise; Actuators shall be designed to be maintenance free during the operational life. Manufacturer shall size the actuator to match the valve torque requirements. For the purpose of sizing the actuators, the torque output with 70 kg/cm2 (g) hydraulic pressure shall be at least twice that required to operate the ball valve under the maximum differential pressure corresponding to the valve ANSI rating. However, the maximum actuator torque output with 105 Kg/Cm2 (g) hydraulic pressure shall not exceed the maximum allowable torque on the valve stem.

3.1.2

3.1.3

3.1.4

3.1.5

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3.1.6

Actuator body shall be designed to comply with ASME B 31.3 and all body joints shall be accordance with ASME Boilers and Pressure Vessels Code, Section VIII, Division-1. All pressure and load carrying components in the actuator shall be designed to withstand the maximum output torque from the actuator without affecting the valve performance. A factor of safety of at least 2.5 on the ultimate tensile strength of materials shall be used for load carrying components that are not covered by ASME B 31.3. Actuator shall be capable of opening or closing the valves within the time calculated based on 0.75 and 3 seconds per inch of valve nominal bore, unless otherwise specified in the process description of work in the bid. Provision shall be made for slower actuation during maintenance and field testing activities. Actuator design and configuration shall be such as to ensure smooth valve operation without imparting any residual lateral loads on the valve stem so as to ensure balanced torque on the valve stem.

3.1.7

3.1.8

3.1.9

3.1.10 Actuators shall be supplied mounted on the valve, unless specified otherwise. In case actuators are not to be mounted on valves, Manufacturer shall supply the actuator loose. These actuators shall normally be stored on a surface facility and will be taken subsea only when required for valve operation. Such actuator shall comply with all requirements of proven design, umbilical connection, torque requirements, etc. as indicated for the actuators to be mounted on the valves. 3.1.11 Actuators shall be supplied with a supply type adopter suitable for mounting on valve stem. Provision shall be made to mount the actuator on the valve in such a way that it can easily be installed or replaced by divers. Actuators, whether permanently mounted on valve or supplied loose, shall be supplied with diver quick release system to facilitate easy removal and installation by divers, when and if necessary. 3.1.12 Open-Close Status indication of sub sea Valve shall be made available on HPU panel through limit switches / proximity switches installed on the valve actuators. Connection shall be provided for the hydraulic fluid supply to the actuator and exhaust hydraulic fluid return to the surface. Hydraulic fluid inlet and outlet connections shall be NPT and all external connections shall be provided on the underside of the actuators to reduce any possibility of damage. It shall be possible for divers to safely make and break the connection between the actuator and HPU umbilical/ Nitrogen cylinder umbilical while the system is pressurized. 3.1.13 For connection with the surface HPU (through umbilical) or with diver held nitrogen cylinder , the actuator body ports shall be connected by tubing to a junction plate consisting of :
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Design Division Engineering Services 11 - High, Mumbai ISO 9001: 2000

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Four No. SS 316 NB quick connect / disconnect coupling made half with self sealing check valves (One primary and one spare set). Four no. SS 316 NB isolation valves, one for each coupling. Four Nos. SS 316 3/8 NPTF drain or flush valves. One no. SS 316 3/8 NPTF by-pass valve. 3.1.14 In case of operation of actuators by divers, suitable arrangement shall be provided to exhaust the hydraulic fluid into the sea. 3.1.15 The hydraulic fluid used for operating the actuators shall be water based , biodegradable type with requisite addition of biocide and shall have a cleanliness level of NAS1638, Class-6. The actuator shall be supplied filled with hydraulic fluid. 3.1.16 Valve position indicator shall be provided as an integral part of the actuator. The indicator shall be in line with the pipeline, when the valve is open and transverse when the valve is closed. The system for indication to the diver shall not have moving parts exposed to sea water and shall be covered by a transparent plate to enable the diver to identify the valve position visually even inn poor visibility conditions. A removable cover shall be bolted to the actuator to prevent marine fouling from obscuring the view of the indicator. 3.1.17 When specified in P&ID/Data Sheet/Specification, provision shall be made for valve open/close status (through actuator and umbilical) at the HPU control panel. Necessary details shall be furnished for Companys approval. 3.1.18 Mechanical stops shall be provided to limit the actuator travel. 3.1.19 Where necessary, seals shall be provided on the actuator body to prevent leakage from the actuator to the environment and to prevent seawater leakage in the actuator body under external hydrostatic pressure. The external hydrostatic pressure considered in design shall correspond to a pressure of 1.5 times the hydrostatic head at the installation location. 3.1.20 Threading shall be NPT as per ASME B 2.1 and flange connections shall be as per ASME B 16.5. The tubing, fitting, valves and disconnect couplings shall be SS 316 stainless steel with fittings swage lock or equivalent. All tubing shall be properly supported and shielded from damage by a suitable protective cover.

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Design Division Engineering Services 11 - High, Mumbai ISO 9001: 2000

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3.2

MATERIALS Actuators shall be supplied with SS 316 L stainless steel trim. Materials of all parts and seals shall be compatible with the operating hydraulic fluid. All materials shall be suitable for permanent installation in subsea environment and all exposed parts shall be resistant to seawater corrosion.

3.3

MANUFACTURERS QUALIFICATION Manufacturer who intends bidding for subsea valve actuators must submit along with the Bid, the relevant information and details as mentioned in 5.8.12 of this specification to establish that the type of subsea actuator offered are field proven for permanent subsea installation in similar service for the last five years and are functioning satisfactorily. Subsea actuators of design not installed in the last five years in similar installation (size, rating and water depth corresponding to applicable valve) and service conditions are not acceptable.

4.0 4.1

MISCELLANEOUS INSPECTION AND TESTING The actuator Manufacturer shall perform all inspection and tests as per the requirements of this specification and the relevant codes at his works. Prior to shipment to valve Manufacturers Works. Such inspection and tests shall be but not limited to the following:

4.1.1 Complete actuator housing with internals including the open/close hydraulic circuits of all actuators shall be subjected to a hydrostatic test, the hydrostatic test pressure shall be as per process requirement of the bid. The test pressure shall be applied for a minimum period of 2 hours. Pressure shall be monitored by chart recorder. No leakage shall be permitted during the test. 4.1.2 Actuator operation test shall be carried out by mounting the actuator on a torque rig, applying the hydraulic pressure of 70Kg/Cm2 (g) and carrying out torque tests every 150 for both open and close strokes. The actuator shall be successfully stroked 5 times in each direction by suitably applying the hydraulic pressure. Torque figures shall be recorded for open and close strokes. Actuator position indicator shall be checked for correct operations during the test. The torque generated shall comply the requirements stated in section 5.0 of this specification. This test shall be carried out on all actuators. It shall be demonstrated that by applying 105 Kg/Cm2 (g) hydraulic fluid pressure, the torque developed does not exceed the maximum permissible stem torque of the valve, on which the actuator is to be mounted. 4.1.3 The actuator including the mounting spool shall be hydrostatically tested externally with a pressure equivalent to 1.5 times design water depth indicated. One actuator from each size shall be tested for 24 hours. The actuator shall be fully stroked i.e.

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open-close-open at least 10 times during this period. All other actuators of the same size shall be hydro tested for a minimum period of 1 hour. There shall be no evidence of internal leakage during the test. 4.1.4 Operation of all actuators with nitrogen cylinders shall be checked, to comply the requirements stated in section 6. 4.2 NON DESTRUCTIVE TESTING REQUIREMENTS 4.2.1 Non-destructive examination of individual actuator material and components, consisting of but not limited to castings, forgings, plate and assembly welds shall be carried out by the Manufacturer. 4.2.2 All castings of pressure containing parts shall be radio graphically examined as per ASTM E-94 and E-186/E-280 or EE-446 as applicable, at quality level 22Tcategory A, B or C defects shall not exceed the severity level for Class 2. Category D, E.F or G defects shall not be accepted. 4.2.3 All forgings shall be ultrasonically examined to ASTM A-609 Quality 1 will be the minimum level of acceptance. 4.2.4 All machined surfaces shall be liquids dye penetrant examined as per ASTM E165. Surface discontinuities shall not be acceptable. 4.2.5 Sealing areas within the actuator body shall be completely inspected by Magnetic particle methods in accordance with ASTM E-709. Surface discontinuities shall not be acceptable. 4.3 VALVE/ACTUATOR ASSEMBLY TEST 4.3.1 After testing of individual actuators has been completed, the actuators shall be mounted on valves. Integrated valve and actuator tests shall be carried out at the Valve Manufacturers Works, in compliance with the requirements stated in relevant Company specifications for subsea ball valves. 4.3.2 Company reserves the right to perform stage wise inspection and witness tests as indicated at Para 6.1 above at Manufacturers works prior to shipment. Manufacturer shall give reasonable access and facilities to the Companys Inspector. 4.3.3 Company reserves the right to require additional testing at any time to confirm or further investigate a suspected fault. The cost incurred shall be to contractorss account. 4.3.4 Inspection and tests performed/witnessed by the Companys Inspector shall in no way relieve the Manufacturer to perform the required inspection and tests. 4.4 EXTENT OF INSPECTION AND TESTING All actuators shall be tested in accordance with the requirements of Section 6.0 of this specification. Actuator operation tests as well as the hydrostatic tests shall be witnessed by the Company Inspector.

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4.5 TEST CERTIFICATES/REPORTS Manufacturer shall submit the following certificates/report: 4.5.1 Mill test certificates relevant to the chemical and mechanical properties of the materials used for the actuator pressure containing parts as per the relevant standard and specifications. 4.5.2 NDT reports for radiography, ultrasonic, magnetic particle and liquid penetrant inspection. 4.5.3 Test report on operation of actuators including torque and operating time. 4.5.4 Test report on internal and external hydrostatic test of actuators. 4.5.5 Test report on actuator/valve assembly tests. 4.5.6 All other actuator test reports and certificates as required by these specifications. 4.5.7 The certificates shall be valid only when signed by Companys Inspector. Only those actuators which have been certified by Companys Inspector shall be dispatched from Manufacturers Works. 4.6 PAINTING AND MARKING 4.6.1 Actuator surface shall be thoroughly cleaned, freed from rust and grease and applied with sufficient coats of corrosion resistant paint suitable for marine environment and suitable for long term sub-sea service. Surface preparation shall be carried out by short blasting to SP-6 in accordance with Steel Structures Painting Council - Visual Standard SSPC VIS-I . Manufacturer shall indicate the type of corrosion resistant paint used in the drawings submitted for Company approval. 4.6.2 In addition to the corrosion resistant paint, entire actuator surface shall be provided with auditable antifouling coating to overcome rapid growth of fouling organisms/marine growth during the operational life of the actuator. Points requiring access during diver operations shall be coated with phosphorescent materials which can absorb the light and retain the glow. So that these points can be easily identified by the diver before operation. 4.6.3 All bolting and nuts exposed to the sea water environment shall be coated with XYLAN /PTFE or shall be plated with Zinc as per ASTM B 633 Type-II SC3. In addition, all threads exposed to sea water shall be provided with plastic caps, to prevent the ingress of seawater. 4.6.4 All actuators shall be marked as per Manufacturers standard and shall have a permanently attached stainless steel name plate with the following details : Tag Nos. Manufacturers Name. Actuator Type, Model No. Serial No.

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Actuator Torque Rating.

Design Water Depth in m Suitable for mounting on valves with Stem size, Valve size, ANSI Rating of Valve.

4.7

SPARES AND ACCESSORIES

4.7.1 Manufacturer recommend spares for the actuator shall be supplied by the contractor considering requirements for commissioning and two years of normal operation. 4.7.2 In addition, Manufacturer shall recommend and submit the list of accessories and special tools required for operation and maintenance of the actuators. 4.8 DOCUMENTATION Following documents shall also be submitted to the company for review along with the PR: 4.8.1 4.8.2 4.8.3 4.8.4 4.8.5 4.8.6 4.8.7 4.8.8 4.8.9 General arrangement and sectional drawings showing clearly the design and materials. features

Technical catalogues giving technical specification and other information for each type of actuators and its accessories. Detailed sectional drawings showing all parts with reference number and materials specification. Assembly drawing with overall dimensional details. Actuator sizing calculations including the relationship between required torque valve and actuator output torque. Welding procedure, testing procedures including the details of actuator torque testing and quality control procedures. Procedure for external hydrostatic test. Details of hydraulic fluid proposed for filling the actuator. Details of quick disconnect coupling system provided on the actuator. Details of corrosion resistant paint, antifouling coating and radium / phosphorescent coating proposed to be applied on the valve surface.

4.8.10 Details regarding the nitrogen quality along with pressure required for operating the actuator from full open to full close under maximum differential pressure corresponding to ANSI valve rating. 4.8.11 Reference list of similar supply of actuators with all relevant details including Project, Year, Client, Location, Size, Relation, Service, Water depth, etc. wherein the actuators have been installed in subsea installation in the last five years. 4.8.12 Contractor shall submit to the company following test certificates / reports as per clause number 4.5 of the specification.
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4.8.13 Manual for installation, erection instruction, maintenance and operation instructions including a list of recommended spares for actuators. 4.9 WARRANTY Vendor shall have final and total responsibility for the design and mechanical performance of all equipment supplied under this specification. Vendor shall warrant the equipment furnished by him and the performance of the said equipment in accordance with this specification. Also refer to Warranty clause as given in bidding documents (Volume I).

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