MADURA BD FIELD DEVELOPMENT – EPCI

PNEUMATIC ON-OFF VALVE AND MOTOR

OPERATED VALVE SPECIFICATION
DOC. NO. GMS-SPT-013 REV. 1

RECORD OF REVISION
The revisions listed below have been incorporated in this copy of the document.

REV. PAGE
SECTION DESCRIPTION OF CHANGES
NO. NO.
Add some abbreviation” AC, PO, UPS, GMS, MCC, and
B 1.3 5
MOV”

Add sentence “For Motor Operated Valve, available power

B 3.3.1 9
will be three phase 400 VAC/50 Hz”

B 4.2 9 Revised type of protection for Electrical Safety

B 4.3, 7.2.7 10, 16 Revised EEx‟d‟ to Ex‟d‟

Add description Pneumatic ON-OFF and description Motor

B 6.2 11
Operated Valve

7.1.1,
B 12, 14 Deleted Limit Switch
7.2..2.2

B 7.2.2.2 14 Revised Actuated Motor Operated Valve

B 7.2.3 15 Revised Valve Body

B 7.2.5 15 Revised description for Leakage Class

0 3.3.1 9 Revised sentences for power supply

0 4.2 9 Revised sentences for selection type of protection

0 4.2 9 Revised sentences for selection type of protection

Revised sentences for selection valve type description

0 6.2 11
(Pneumatic On Off Valve)
Revised sentences for selection valve type description (Motor
0 6.3 11
Operated Valve)

0 7.2.2.2 14 Revised sentences for Actuator Motor Operated Valve

0 7.2.2.2 14 Revised sentences for Actuator Motor Operated Valve

0 7.2.5 15 Revised sentences for leakage class

Delete the sentence “and motor operated valves, as a

1 7.2.6 15
minimum”

MADURA BD FIELD DEVELOPMENT - EPCI 2 of 20

CONTRACT NO : 332000002
 MADURA BD FIELD DEVELOPMENT – EPCI
PNEUMATIC ON-OFF VALVE AND MOTOR
OPERATED VALVE SPECIFICATION
DOC. NO. GMS-SPT-013 REV. 1

TABLE OF CONTENT

1.0 INTRODUCTION ................................................................................................................................ 5

1.1 General .................................................................................................................................. 5

1.2 Scope .................................................................................................................................... 5
1.3 Definitions and Abbreviations ............................................................................................ 5

2.0 REFERENCES ................................................................................................................................... 6

2.1 International Codes & Standards ....................................................................................... 6

2.2 Indonesian Codes and Regulations ................................................................................... 7
2.3 Project Documents .............................................................................................................. 7
2.4 Omissions and Conflicts ..................................................................................................... 8

3.0 ENVIRONMENTAL CONDITIONS AND AREA CLASSIFICATION ................................................. 8

3.1 Hazardous Area Classifications ......................................................................................... 8

3.2 Environmental Data ............................................................................................................. 8
3.3 Utilities Data ......................................................................................................................... 9

4.0 ELECTRICAL SAFETY IN EXPLOSIVE ATMOSPHERE. ................................................................ 9

4.1 General .................................................................................................................................. 9

4.2 Selection of Type of Protection .......................................................................................... 9
4.3 Unclassified Locations ........................................................................................................ 9
4.4 Safe Locations ................................................................................................................... 10

5.0 DESIGN LIFE AND RELIABILITY ................................................................................................... 10

6.0 TECHNICAL REQUIREMENTS ....................................................................................................... 10

6.1 General ................................................................................................................................ 11

6.2 Valves Type Description ................................................................................................... 11
6.3 Sizing and Selection .......................................................................................................... 11
6.4 Actuator Material................................................................................................................ 12

7.0 DESIGN AND CONSTRUCTION ..................................................................................................... 12

7.1 General ................................................................................................................................ 12

7.2 Design Criteria ................................................................................................................... 13

8.0 DOCUMENTATION .......................................................................................................................... 19

8.1 Approval Documentation .................................................................................................. 19

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 MADURA BD FIELD DEVELOPMENT – EPCI
PNEUMATIC ON-OFF VALVE AND MOTOR
OPERATED VALVE SPECIFICATION
DOC. NO. GMS-SPT-013 REV. 1

8.2 Final Documentation ......................................................................................................... 19

9.0 WEIGHT CONTROL ......................................................................................................................... 20

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CONTRACT NO : 332000002
 MADURA BD FIELD DEVELOPMENT – EPCI
PNEUMATIC ON-OFF VALVE AND MOTOR
OPERATED VALVE SPECIFICATION
DOC. NO. GMS-SPT-013 REV. 1

1.0 INTRODUCTION
1.1 General
Husky-CNOOC Madura Ltd. (HCML) plans to develop the Madura Strait Block BD gas reserves for
sales gas to buyers in Java Island. This field is located offshore in the Madura Strait East Java,
about 65 km east of Surabaya and about 16km south of Madura Island. The project envisages
development of a wellhead platform; an offshore spread moored Floating, Production, Storage, and
Offloading (FPSO) barge with gas processing facilities; Gas metering Station (GMS); flexible risers
from wellhead platform to FPSO and Export gas pipeline from WHP to GMS.
The facility is designed for 110 MMSCFD sales gas. An unmanned wellhead platform with four well
slots and two slots for future expansion would be set in 182 feet of water.
The onshore gas reception and metering facility is installed prior to tie-in to the gas buyer‟s pipeline
The Gas Metering Station facility will include the provision of a 4 (four) metering skid with orifice
meter type (Two (2) metering skid are designed for 40 / 30 MMscfd, one (1) metering skid is
designed for 30 MMscfd, and one (1) standby metering skid designed for 40 MMscfd) including
piping, valves and fittings and other accessories : Gas Inlet KO Drum, Filters; automatic shutdown
valves to fully isolate the facilities; control valve; control building with flow computers, power
distribution, UPS system, Emergency Diesel Generator including diesel day tank, and other
equipment/accessories to support the operation of the facility.

1.2 Scope
This specification covers the minimum requirements for the design, procurement, material,
fabrication, inspection & testing, protective coating, preparation for shipment, and delivery of
Pneumatic ON-OFF Valve and Motor Operated Valve valves complete with their actuator assemblies
to be installed for Gas Metering Station (GMS) in Madura Strait Block BD Development Project.
The Vendor shall clearly identify any deviation to this specification, and the references codes,
standard and Company specifications, and list them, with references to the document clause, in the
quotation. In absence of any specific mentioning of the deviations, it shall be assumed that the
vendor shall fully comply with all the specifications and codes referenced herein.
It shall be the responsibility of the Vendor to provide a complete, tested, individual valve assembly
including, but not limited to the valve, actuator, instrument pneumatic and hydraulic system
assemblies, and limit proximity switches.
The Vendor‟s scope of supply shall include but not be limited to the following as a minimum:
a. Design, fabrication, and supply of the following :
- Pneumatic ON-OFF Valves
- Motor Operated Valves
b. Inspection, testing, and precommissioning at Vendor‟s works
c. Vendor documentation
d. Vendor assistance for Installation & precommissioning at Contractor‟s fabrication yard
e. Vendor assistance for start-up onshore
f. Commissioning spares
g. Special tools for Installation, operation, and maintenance

1.3 Definitions and Abbreviations

For the purpose of understanding this specification, the following definitions apply.

MADURA BD FIELD DEVELOPMENT - EPCI 5 of 20

CONTRACT NO : 332000002
 MADURA BD FIELD DEVELOPMENT – EPCI
PNEUMATIC ON-OFF VALVE AND MOTOR
OPERATED VALVE SPECIFICATION
DOC. NO. GMS-SPT-013 REV. 1

Definitions
COMPANY : This shall mean Husky CNOOC Madura Ltd
CONTRACTOR : This shall mean EPC CONTRACTOR
VENDOR : This vendor of the equipment defined in the specification
PURCHASER : COMPANY / CONTRACTOR WHO ISSUES A Purchase Order
on Vendor.
Abbreviations
AC : Alternating Current
PO : Purchase Order
PCS : Process Control System
SIS : Safety Instrumented System
UPS : Uninterruptible Power Supply
GMS : General Metering Station
RTJ : Ring Type Joint
MDR : Manufacturer Data Report
MOV : Motor Operated Valve
MCC : Motor Control Center
MTBF : Mean Time between Failures
MTTR : Mean Time to Repair
MAAT : Maximum Allowable Actuator Torque
MAST : Maximum Allowable (valve) Stem Torque

2.0 REFERENCES
The pneumatic On-Off valves and motor operated valves shall be designed and fabricated in
accordance with accepted design practices and applicable sections of the latest edition of the listed
specification, codes, and standards, including any and all modification and interpretation.

2.1 International Codes & Standards

In addition to the above mentioned specifications, the latest editions of the following codes and
standards are referenced and are considered a part of this specification.

API (American Petroleum Institute)

API 6D Specification for Pipeline Valves
API 6FA Fire Test for Valves
API 6FB Fire Test for End Connections
API 598 Valve Inspections and Test
API 607 Fire Test for Soft Seated Ball Valves

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PNEUMATIC ON-OFF VALVE AND MOTOR
OPERATED VALVE SPECIFICATION
DOC. NO. GMS-SPT-013 REV. 1

IEC (International Electrotechnical Commission)

IEC 60079 Electrical Apparatus for Explosive Gas Atmosphere
IEC 60617 Graphical Symbols for Diagrams
IEC 61508 Functional safety of electrical/ electronic/ programmable electronic safety-
related systems
IEC 61511 Functional safety of safety instrumented system for the process sector
IEC 60331 Fire resistant cable tests

British Standard (BS)

BS 6755 (Part-1) Specification for Production Pressure Testing Requirements
BS 6755 (Part-2) Testing of Valves
B.S EN 10204 Certification of Material Testing
BS 5345 Selection, Installation, Maintenance of electrical apparatus for use in
potentially explosive atmosphere

ASME (American Society of Mechanical Engineers)

ASME/ANSI B16.34 Valves Flanged, Threaded and Welding End
ASME B 16.5 Steel Pipe Flange and Flange Fittings

American Standard Testing and Material (ASTM)

ASTM A269-82 Stainless Steel Tube

2.2 Indonesian Codes and Regulations

 Government Regulation of Republic of Indonesia No. 19, 1973 (LN of 1973 No. 25, TLN No.
3003 concerning Mining Work Safety Regulation and Control).

 Government Regulation of Republic of Indonesia No. 11, 1979 (LN of 1979 No. 18, TLN No.
3135 concerning Work Safety in Oil and Gas Refining and Processing).

 Decision of Director General for Oil and Natural Gas no. 36/KTPS/DJ/MIGAS/1977.

 Technical Directorate of Oil and Natural Gas Letter No. 008/380/DMT/1988.

 Directorate General Oil and Natural Gas (MIGAS) Regulation No. 43P/382/DDJM/1992 for
Terms and Conditions for Appointment of third party MIGAS Guidelines under Regulation no.
06P/0746/M.PE/91.

2.3 Project Documents

GMS-SPM-001 : Piping Material Specification
GMS-SPT-007 : General Instrument Specification
GMS-SPT-010 : Instrumentation for Equipment Packages
GMS-BDT-001 : GMS Instrumentation Design Basis

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PNEUMATIC ON-OFF VALVE AND MOTOR
OPERATED VALVE SPECIFICATION
DOC. NO. GMS-SPT-013 REV. 1

2.4 Omissions and Conflicts

Any omission in the requirements detailed herein shall not relieve the VENDOR of his responsibility
to deliver equipment in accordance with the specified performance.
If VENDOR finds conflict between documents or has any doubts on specified requirements, these
shall be communicated immediately to COMPANY in writing. Work related aspects should not
proceed until VENDOR receives clarification from COMPANY in writing. Verbal communications
shall not be considered official.
In the event of a conflict between this specification and any requirements of statutory and safety
regulations, codes and standards and other documents, the most stringent shall prevail. The order
of priority of project documents shall be as follows:
 Indonesian Codes and Regulations

 Technical Requisition including functional specification and data sheets

 This specification

 Other Project specifications

 International codes and standards

All apparent conflicts shall be reported to the CONTRACTOR in writing for resolution. The
CONTRACTOR / COMPANY decision shall be final.

3.0 ENVIRONMENTAL CONDITIONS AND AREA CLASSIFICATION

3.1 Hazardous Area Classifications

Hazardous area classification for the GMS shall be in accordance with API RP 505.
The gasses likely to be present in areas designated as hazardous will be a combination of heavier
and lighter-than-air gasses.
All equipment intended for use in hazardous areas shall be tested and certified for operation in the
required zone by an international, recognized testing authority in accordance with API RP 505
requirements.

All equipment shall be rated for the location installed. All equipment in Gas Metering Station shall be
rated for Class I, Zone 2, Gas Group IIA, temperature class T3. All instrument analyzers in the field
shall be explosion proof suitable for the area classification. In addition, all equipment shall be
designed for an outdoor, salt-laden, tropical, marine environment.

Refer to area classification drawing for further details: Drawing No. GMS-16005, GMS Hazardous
Area Classification Drawing

3.2 Environmental Data

Meteorological and Environmental Data
Design maximum ambient temperature (dry bulb): 96 °F
Design minimum ambient temperature (dry bulb): 58 °F
Design sun-exposed temperature: 120 °F

MADURA BD FIELD DEVELOPMENT - EPCI 8 of 20

CONTRACT NO : 332000002
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PNEUMATIC ON-OFF VALVE AND MOTOR
OPERATED VALVE SPECIFICATION
DOC. NO. GMS-SPT-013 REV. 1

Maximum relative humidity: 86.1 %

Wind design velocity: 115 mph
Atmospheric pressure: 14.7 psia
Other factors: Tropical, Offshore, Salty, Very Humid
The field instruments and controls, including the panel, shall be suitable for operation in the open
where temperature and relative humidity can go as high as 96°F and 86.1%, respectively.
Temperature, humidity, and salt content in the atmosphere are ideal for fungus growth and
corrosion. Instrumentation, controls, and systems shall be able to operate continuously without
their normal physical and functional reliability being affected by the tropical environment.
Tropic proofing shall be accomplished by selection of materials not susceptible to fungus growth
or moisture. Treatment of any susceptible materials shall be with a protective coating to prevent
the growth of fungus, to prevent corrosion and to prevent absorption of moisture. Varnish used
for the treatment of instrumentation equipment and components shall conform to military
specification (USA) MIL-V-173 or suitable substitute with prior approval of Buyer.

3.3 Utilities Data

3.3.1 Power Supply
Motor Operated Valve available power will be three phase 400 VAC/50 Hz. 230 VAC power shall be
designed / supplied from normal and UPS feeder to add to the reliability of the system (PCS or SIS).
The CONTRACTOR shall supply AC junction boxes on the meter skid and AC terminal strips in the
meter panel. Further distribution of 24 VDC or other voltages requirement shall be under vendor
scope.
3.3.2 Instrument Air Supply
The instrument air system shall normally operate at 100 psig.

4.0 ELECTRICAL SAFETY IN EXPLOSIVE ATMOSPHERE.

4.1 General
In order to prevent electrical apparatus, including electronic instrument, from becoming a source of
ignition in potentially explosive atmosphere, protective measures shall be taken.

4.2 Selection of Type of Protection

Electrical installation for gas atmospheres shall be in accordance with IEC 60079-14.
All field electronic instruments shall comply with requirements of the hazardous area classification in
Class I, Zone 2, Gas Group IIA, T3, equipments generally certified to‟ Ex‟d
The degree of protection for field equipments enclosures shall be in accordance with the IEC 60529.
The minimum degree of protection for junction boxes shall comply with the area classification and be
weatherproofed to IP66.

4.3 Unclassified Locations

All field instruments located in unclassified area shall be certified to Ex‟d‟ and ingress protection IP
66 as a minimum
Unit control panels (UCP) located in the field in an unclassified area shall be certified to ATEX Cat-
3 and ingress protection IP 66 as a minimum.

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CONTRACT NO : 332000002
 MADURA BD FIELD DEVELOPMENT – EPCI
PNEUMATIC ON-OFF VALVE AND MOTOR
OPERATED VALVE SPECIFICATION
DOC. NO. GMS-SPT-013 REV. 1

4.4 Safe Locations

All control panels/cabinets located in indoor location, safe area, like control room, and instrument
room shall be certified to IP41 as a minimum.

5.0 DESIGN LIFE AND RELIABILITY

The design service life of the Gas Metering Station (GMS) and all associated equipment and
systems shall be 20 years old.
The vendor shall demonstrate the overall availability and reliability of the complete units.
Prototype or unproven equipment not having a well-established operating record not be considered.
The Vendor shall be required to meet an agreed specific minimum availability figure, either to enable
a particular machine configuration to be practicable or for operating reasons. In addition, the Vendor
shall furnish their best estimates of Mean Time Between Failures (MTBF) and Mean Time To Repair
(MTTR) for the equipment concerned.
In making assessments of the availability and reliability, the vendor will need to estimate
maintenance and repair times. For the purpose of making such estimates, the Vendor will need to
estimate maintenance and repair times. For the purpose of making such estimates, the Vendor may
assume that the spares holding is in accordance with their submitted recommendations unless
otherwise stated. The Vendor may also neglect any delay caused by factors not directly related to
the unit in question, unless a basis for estimating such delays is provided by the Principal. In the
case of failure modes, which make a significant contribution to the overall plant availability, the
Vendor may be required to demonstrate that their assumed repair times can be achieved.

6.0 TECHNICAL REQUIREMENTS

All equipment shall be strictly in accordance with data sheets, drawings, specifications, codes, and
standards.
Compliance by the Vendor with the provisions of this specification does not relieve him of his
responsibility to furnish or specify all equipment and accessories and instruments of a proper design
to meet the specified process condition and / or local codes governing health and safety.
Applicable documents are attached with the request for inquiry. However, if the Vendor is not in
possession of any of the listed or referenced Company documents, it shall be his sole responsibility
to obtain them from the purchaser. Otherwise, it shall be assumed that the Vendor has received,
read and understood the total content of the inquiry/ PO
Vendor shall submit detailed calculations for the design of each item of equipment including all
components and appurtenances for Purchaser approval prior to fabrication. The calculation as follow
but not limited to:
 Open and Close Stroking Time
 Torque Calculation
 Power consumption for each Motor Operated Valve (MOV)
Vendor also shall state all the utilities requirements/consumptions.
Where the Vendors scope includes the fabrication of a base frame, earthing bosses shall be installed
at diametrically opposite points.

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CONTRACT NO : 332000002
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PNEUMATIC ON-OFF VALVE AND MOTOR
OPERATED VALVE SPECIFICATION
DOC. NO. GMS-SPT-013 REV. 1

6.1 General
All valves shall be suitable for installation in outdoor, unprotected locations, and shall be adequately
protected from corrosion likely to occur due to exposure to marine environment and adverse weather
conditions. Valve and accessories shall be able to withstand exposure to wind driven dust, saline
damp air, and high ambient temperatures.
The valves shall be supplied fully assembled and tested and capable of operating in automatic mode
and shall require minimum maintenance.
All valves shall be dust proof, fungus proof, and vermin proof using accessories such as bug screens
and protective coatings.
All materials shall be suitable for service in the process temperature, pressure range, and fluid
properties stated in data sheet.
Valves shall be of a proven design and shall have demonstrated leak-tight shut off. The
opening/closing times shall be as per data sheet / specifications.
Vendor shall provide the data regarding Probability of Failure on Demand (PFD) values for the
Actuated ON-OFF Valve and Motor Operated Valve.
The Vendor shall provide information, where indicated, on the Purchasers data sheets.

6.2 Valves Type Description

Pneumatic ON-OFF Valve
Pneumatic ON-OFF Valve type as per P&ID and data sheet consists of a valve and a pneumatic
actuator. Actuated ON-OFF Valve is exclusively controlled by the PCS system.
The typical Pneumatic ON-OFF Valve construction consist of actuator, solenoid valve, position
transmitter, instrument air supply, and valve itself. Pneumatic ON-OFF Valve generally ball valve
type. Failure position shall be as stated on valve data sheets and P&ID‟s.
Motor Operated Valve
Motor Operated Valve type shall as per P&ID and datasheet, consist of valve and electric motor
actuator.
The typical MOV constructions consist of electric motor actuator, gear box, and the valve itself.
Motor Operated Valve generally ball valve type. First of all, the motor is turned on when AC power is
applied to it. The motor rotation is transferred through a gear mechanism to the output thrust part.
The output thrust is then transferred to the gear mechanism in the gear box to rotate the valve stem.
Motor Operated Valve failure position shall be last position as stated on valve data sheets and
P&ID‟s.

6.3 Sizing and Selection

The Vendor shall submit for Purchaser‟s approval, individual actuator torque calculations (Break to
Open Torque, Break to Close Torque, Run Torque, End Torque) together with individual valve torque
calculations. These shall be based on the extreme process condition as specified in the data sheet.
The Vendor shall also verify that actuator torque is less than that required to shear the valve stem
during stalled / stuck conditions (valve frozen)
Extreme process pressure is defined as maximum upstream pressure with the valve closed and the
downstream side vented to atmosphere. Extreme process temperature shall be that temperature,
either maximum or minimum, that creates the maximum valve torque conditions.
Maximum permissible noise level for pneumatic on-off valve shall be 85 dB at 3 feet from the valve.

MADURA BD FIELD DEVELOPMENT - EPCI 11 of 20

CONTRACT NO : 332000002
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PNEUMATIC ON-OFF VALVE AND MOTOR
OPERATED VALVE SPECIFICATION
DOC. NO. GMS-SPT-013 REV. 1

The vendor shall select valves and actuators from his standard range that is in accordance with data
sheets, data sheets notes, and this specification.
The required stroking times for each valve shall be detailed on the data sheet. The vendor shall state
if ancillaries such as flow controls or quick exhaust are included to achieve the specified valve
opening and closing times.

6.4 Actuator Material

Actuator material shall be as specified on the data sheets and shall be in accordance with the
manufacturers standards. The material of the actuator body and spool piece shall be
electrochemically compatible with the material of the valve body.
Actuator and parts shall be painted in accordance with the vendor standard painting and
coating specifications relevant to the site of installation.
Protective compounds and durable coating shall be used to prevent corrosion in addition to
protection of external parts.
Actuator internal shall be Electro less Nickel Plated (ENP) to reduce friction and protect from
corrosion.
Actuators shall meet all applicable codes, safety restrictions, application practice.
The actuator shall exhibit excellent corrosion resistance confirmed by salt spray testing per ASTM
B17.
Actuators shall be designed with an ingress protection of IP 66 minimum.
The actuator size and torque requirement shall be calculated by the vendor.
The pneumatic on-off actuator shall be pneumatic spring return type. The actuator “spring return”
shall be pre stressed.
MOV actuators fail shall to the last position on loss of power supply.
Instrument actuated on-off valve actuators fail action shall be refer to P&ID.
The Vendor shall submit, for approval, a list of spare parts specifying the material of manufacturer
of each valve

7.0 DESIGN AND CONSTRUCTION

7.1 General
7.1.1 Extent of Supply
The Vendor shall furnish all components and ancillary equipment necessary to make the
pneumatic On-Off valves and motor operated valves complete, safe, and ready for operation. The
equipment shall include, but not be limited to the following for all valves, unless stated otherwise:
 Valve Body
 Actuator
 Solenoid Valve (Not Applicable for MOV)
 Air regulators, filters, bug screens, quick exhausts, check valves, and mufflers (Not
Applicable for MOV)
 Ancillary Equipment

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CONTRACT NO : 332000002
 MADURA BD FIELD DEVELOPMENT – EPCI
PNEUMATIC ON-OFF VALVE AND MOTOR
OPERATED VALVE SPECIFICATION
DOC. NO. GMS-SPT-013 REV. 1

Sufficient descriptive information shall be furnished with the Vendor's Tender Document to enable
equipment size, weight, performance, quality, capacity, and specification adherence to be
determined.
7.2 Design Criteria
7.2.1 General
Flow direction shall be clearly indicated by an arrow on the body as part of valve casting for uni-
directional valves or those with a preferred flow direction. Alternatively, the valve shall be clearly
marked with the manufacturer's recommended high-pressure side.
Valves shall be no smaller than the line size.
The following guidelines shall be used in the selection of valve body types. Other specific
requirements shall take precedence over these guidelines.
Ball valves may be resilient seated, provided the temperature is below 400 F and the service is
clean. Otherwise a metal seated design is required. Metal seated ball valves shall have electroless-
nickel plating or chrome plating on the ball.
Pneumatic On-Off Valve and Motor Operated Valve (MOV) shall be ANSI 150 RF as minimum.
Valves in hydrocarbon service shall be fire-safe in accordance with API 607 or API 6FA.
Valve body construction shall be as per piping specification GMS-SPM-001 and shall be in
accordance with API 6D.
7.2.2 Operators (Actuators)
7.2.2.1 Pneumatic On – Off Actuator
The valve operator shall be a self-contained unit designed for top mounting on the valve stem,
except for butterfly valves which may have the operator mounted on the end of the horizontal shaft.
The preferred operator orientation is with the valve in horizontal pipe and the operator oriented
parallel to the process line. The Vendor shall submit an assembly drawing for Buyer review and
approval.
The Vendor shall submit calculations that confirm that the operator will open and close the valve
with the differential pressure and temperature as noted on the individual data sheets. As a
minimum, the operator shall be sized with a safety factor of one hundred and thirty percent (1.3
times the maximum valve torque requirement) for butterfly valves and one hundred and fifty
percent (1.5 times the maximum valve torque requirement) for ball valves.
Generally, operators shall be pneumatic spring-return (rack and pinion, vane, or scotch yoke),
pneumatic double-acting cylinder types.
Pneumatic valve operators shall be quarter turn type valves, spring opposed rack and pinion type,
vane type or scotch-yoke type cylinder actuators totally enclosed design with no external moving
linkages.
The actuator shall be capable of 100 rotation and shall include open and closed position stops
with a minimum of 20 total travel adjustment.
The actuator shall be rated for continuous operation using dry instrument air and suitable for
mounting in any position.
Actuators shall be non-breathable and not to draw sulphurous air into cylinders when operated.
To meet the fail-safe requirement, actuator shall be spring return type.
When a volume tank is required, it shall be sized to stroke the valve a minimum of three full
strokes, assuming an initial bottle pressure of 80 psig.
Local position indicators shall be shaft mounted and visible from 3 meters (10 feet).

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CONTRACT NO : 332000002
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PNEUMATIC ON-OFF VALVE AND MOTOR
OPERATED VALVE SPECIFICATION
DOC. NO. GMS-SPT-013 REV. 1

Solenoid valves shall be furnished mounted on the valve and pretubed

The sizes, types and tag numbers of the valves required are listed in the Instrument Data
Sheets. All valves shall be fitted with a permanently affixed stainless steel nameplate and shall
have the valve Tag Number, Service, Purchase Order Number, Date of Manufacturer, etc. This
tag is additional to the Vendor's model number and other data name plate. The tag plate shall
be a minimum of 1" (L) x 2" (W) x 1/16" (T). The field tags shall be attached with 16 AWG
Stainless Steel wire or SS drive screws.
When required ancillary equipment such as solenoids and position transmitter shall be fitted
with permanently affixed stainless steel labels with tag numbers engraved.
The Vendor shall advise with Tender estimated weights for each valve actuator assembly.
The Vendor shall ensure vertically mounted valves are adequately designed to prevent undue
stress on the shaft.
7.2.2.2 Actuator Motor Operated Valve
Vendor shall be responsible for correct sizing and selection of motor operated actuator. Vendor
shall provide sizing calculations for approval.
Motor operated valves shall be supplied complete with gear box and hand wheel for emergency
operation.
Local control units shall be supplied complete with push-buttons for open, close and stop.
Motors shall be provided with adjustable torque switches to protect against overloading.
The torque output of the actuator shall be equal to twice the torque required for the valve to
open or close at the stated differential pressure (whichever the greater of the two).
Overload protection and limit stops shall be provided in both directions.
The necessary local/remote selector switch, start/stop control or push buttons etc. shall be
provided on actuator for local/remote control depending on the mode of selection. In case of
failure for torque (torque switch) the mechanical design shall be adequate to stall and trip the
motor without damage. The actuator shall be provided with an anti-condensation heater.
The motors shall be provided with „Class F‟ insulation with temperature rise limited to „Class B‟.
The hand-wheel shall be geared type and the locking type with a declutching mechanism. The
operating force shall be limited 245 N (25 KGF) at the hand-wheel rim
The MOV shall be suitable for starting at 75% voltage across the motor terminal, without
exceeding the permissible temperature rise in any part of the motor. Protection against motor
overheating shall be an integral part of the motor itself.
MOV‟s shall have interface to DCS system for status display, interlocking and monitoring.
Motor shall be three phases 400 VAC, 3 phase, 3 wire, 50 Hz squirrel cage induction motor, as
per spec for low voltage induction motors. All other on board transformed / rectified power
requirements shall be derived from this power source. The actuator design shall ensure
adequate segregation between voltage levels.
The motor shall be rated for 15 minute duty and shall conform to international standards.
The motor shall be provided with thermostat(s)/thermistor(s) embedded in hot spot of motor
winding.
The actuator shall include a local starter with a reversing contactor, a local/stop/remote control
selector switch, open/close push buttons, local open / close indications, an adjustable torque
limiter.
The remote / off / local selector shall be fitted with a key lock to prevent unauthorized operations
of the valve. Local operation shall be by the push buttons. Remote operation will be by hard
wired signals from PCS/SIS.

MADURA BD FIELD DEVELOPMENT - EPCI 14 of 20

CONTRACT NO : 332000002
 MADURA BD FIELD DEVELOPMENT – EPCI
PNEUMATIC ON-OFF VALVE AND MOTOR
OPERATED VALVE SPECIFICATION
DOC. NO. GMS-SPT-013 REV. 1

Actuator motor and other accessories shall be certified to the hazardous area specified in the
project documents. In addition to this the actuator shall be weather-proof to IP 66. Minimum
certification shall be Class 1 Zone 2, Gas Group IIA, T3.
7.2.3 Valve Body
Valve body shall generally be butt well or flanged end. Flange facing for sizes up to and including
24” shall be to match ASME B16.5; for those above 24” they shall match ASME B16.47 series
„A‟. Flange Rating shall be in accordance with the valve data sheet and line class.
Flange Finish shall be RF smooth serrated spiral finish (125-250 μinch) for class 150 to 600.
Flange facing finish shall be RTJ for class 900 and above.
Preferably all ball valves shall be trunnion mounted for sizes equal to or greater than the
following: Supplier shall clearly mention trunion selection criterion in the offer.
 150# - 300# size ≤ 2” is floating ball
 150# - 300# size > 2” is trunnion ball
 Rating greater than 300# and size greater than 2” is trunnion mounted ball valve
7.2.4 Material Selection
The Vendor shall ensure that all materials offered for valve bodies, flanges, trim and soft goods
are in complete compliance with the individual valve specifications stated in GMS-SPM-001,
"Piping Material Specification Line Class -Process and Utility Piping". The required valve
specification number is stated on the individual instrument data sheets. Where any conflict exists
for material selection between GMS-SPM-001, this specification and the datasheets, then the
data sheets shall take precedence.
The Vendor shall provide a compliance statement with the tender stating that all valve materials
are offered in compliance with data sheets. Where alternatives are offered these shall be
detailed as non-conformances in the tender.
7.2.5 Leakage Class
The shut-off valve leakage shall be accordance with API 598 with shut-off class shall be Class as
per datasheet.
7.2.6 Sizing Criteria for Pneumatic Operator
Actuator shall be sized for a minimum air supply pressure of 80 psig and 130 % of the required
valve reseat / break torque when the valve is closed against maximum differential pressure. The
vendor shall guarantee that the equipment shall not be damaged with an air supply pressure of
160 psig or make suitable provisions to withstand that pressure.
The instrument air supply for the actuator is 80 psig minimum, 100 psig normal, and 150 psig
1 maximum. Actuator shall be designed to withstand maximum pressure. Valve closing time shall
be based on a speed of 1 second per inch of nominal pipe diameter for pneumatic On Off Valves
and Motor Operated valves, as a minimum.
Actuator shall be sized without the necessity for pressure relieving devices. Actuator orientation
shall be as per as per datasheet details.
The Vendor shall provide Valve / Actuator orientation sketches post award to enable the
purchaser to select the required valve and actuator orientation prior to valve actuator assembly.
The Vendor shall offer standard interchangeable position mounting for the instrument air and
solenoid assemblies.
7.2.7 Ancillary Equipment for Pneumatic On-Off Valve
All ancillary equipment, except for proximity switches shall be mounted on a rigid 316 stainless
steel plate which shall be securely bolted on the actuator. Devices such as restrictors and quick

MADURA BD FIELD DEVELOPMENT - EPCI 15 of 20

CONTRACT NO : 332000002
 MADURA BD FIELD DEVELOPMENT – EPCI
PNEUMATIC ON-OFF VALVE AND MOTOR
OPERATED VALVE SPECIFICATION
DOC. NO. GMS-SPT-013 REV. 1

exhausts may be mounted in line. The Vendor shall ensure dissimilar metals are adequately
segregated to prevent galvanic corrosion.
When applicable, proximity switches shall be contained in a single housing and shall be arranged
to operate directly off the Centre shaft. Electric type proximity switches shall have the following:
 Anti-corrosion sealed fully proven construction
 Contact: 0.5A @ 24 VDC (two SPDT), proximity type
 Electrical entry shall be 3/4" NPTF
 Certification Ex'd' Proximity switch contacts will be as per the following table :
Table 1.1 – Proximity switch contacts
Valve Open Limit Proximitor Valve Closed Proximitor
Valve Closed Open Closed
Valve Open Closed Open
Valve in Travel Open Open

Actuator deterioration due to corrosion from ingress of wet salt laden air is of specific concern.
The Vendor shall submit with tender a proposed method of preventing the ingress of wet salt
laden air into the actuator internal chambers or clarify how the actuator is protected against
corrosion. Closed and lor lubricated systems shall be considered.
Tube shall be 316 stainless steel minimum 3/8" OD x 0.049" WT. All instrument tube fittings shall
be Swagelok double ferrule 316 SS compression type. All tubing shall be adequately supported.
Solenoid valve bodies shall be AISI 316 Stainless steel. Valve trim shall be stainless steel with
Viton or similar resilient seat to provide tight shut off, 24 VDC electrical power, 5 Watts max rating
unless otherwise specified, complete with suppression diode and shall be suitable for Hazardous
area classification Ex‟d‟ Solenoid valve vent ports shall be fitted with stainless sintered metal bug
screens.
Screwed terminals shall be provided for all electrical connections to the solenoid valves and
position switches. All cable entries shall be 1/2” NPT preferable on Ex‟d‟ casing. Others shall
provide cable glands.
All pneumatic ancillary equipment shall suitable for 3/8" NPT(F) air supply connections.
All valve actuators shall be fitted with local mechanically driven position indication (beacon) flags
painted red in color for the closed position and indicating green for the open position. Where
specified in P&ID the solenoid valve shall be provided with manual reset or/and manual over ride.
Pilot valve and quick exhaust valve shall be Versa make and material shall be 316 SS. Wherever
required.
Material of construction for ancillaries such as fittings, flow restrictors, etc. shall be 316 SS
7.2.8 Torque / Thrust Characteristics.
The torque / thrust characteristics of the actuator in its line application including static and
dynamic pressure effects shall be determined to be compatible with the valve VENDOR‟s quoted
torque / thrust curves, taking into account the size of valve, valve stem size and type, rating, and
construction.
Torque definition for quarter turn valves
BTO - Break to open torque / break away torque (highest torque required by quarter turn valve) -
start opening from fully closed position
ETO - End to open torque - fully open

MADURA BD FIELD DEVELOPMENT - EPCI 16 of 20

CONTRACT NO : 332000002
 MADURA BD FIELD DEVELOPMENT – EPCI
PNEUMATIC ON-OFF VALVE AND MOTOR
OPERATED VALVE SPECIFICATION
DOC. NO. GMS-SPT-013 REV. 1

RT - Running torque
BTC - Break to close torque - start closing from fully opened position
ETC - End of close torque - fully closed
VENDOR shall provide, at the time of quotation, the following torque data in tabular form along
with the quotation:
Minimum requirement for pneumatic torque performance table
 Valve size, rating ,and type
 Shutoff DP used for actuator sizing Torque required by valve (BTO, ETO, RT, BTC, ETC)
 Actuator type
 Instrument air pressure used for actuator sizing
 Torque delivered by actuator (BTO, ETO, RT, BTC, ETC)
 Safety factor for all the position (opening, running, and closing)
 Valve MAST (Maximum Allowable Stem Torque)
 Maximum torque developed by actuator
 Opening / closing time
All items in the load path between valve seat and actuator shall be capable of withstanding the
maximum torque / thrust produced by the actuator without exceeding allowable stresses or being
subjected to unacceptable deflections. Maximum torque shall be determined at maximum air
supply. Actuator must never be able to apply torque above MAST of valve / stem. There shall be
generous degree of safety between MAST and Maximum Allowable Actuator Torque (MAAT).
7.2.9 Material Certification
All materials shall be provided with certificates proving that the material furnished meets the
requirements of the specification and the grade to which it is to be supplied.
The material certification types and traceability levels shall be as per EN 10204, edition 2004.
Certification for pressure containing parts shall be as per EN 10204 type 3.1 and all other wetted
parts to type 2.2.
7.2.10 Approved Manufactures
The approved project valve manufacturers are detailed in the Approved Manufacturer List. The
Vendor shall ensure the actuator / Valve coupling bolting material is of non-corroding steel.
7.2.11 Inspection and Testing
7.2.11.1 QA/QC Certification
Vendor shall provide the QA/QC Test and Inspection Certificates / Reports for the complete
supply:
a) QA/QC Certification for Visual controls:
 Type and model
 Material
 ANSI Rating
 Labeling
 Painting
 Dimensions (flanges, threading, piping)

MADURA BD FIELD DEVELOPMENT - EPCI 17 of 20

CONTRACT NO : 332000002
 MADURA BD FIELD DEVELOPMENT – EPCI
PNEUMATIC ON-OFF VALVE AND MOTOR
OPERATED VALVE SPECIFICATION
DOC. NO. GMS-SPT-013 REV. 1

 Certificate of conformity for equipment used in hazardous areas

b) QA/QC certification for Tests:

Valves Manufacturers shall test each pneumatic on-off valve and motor operated valve at
factory against the specification and data sheet requirements.
Each pneumatic on-off valve and motor operated valve shall have test certificates, which
shall include:
 Materials
 Valve‟s body hydro test
 Valve‟s seat leakage test
 Valve‟s opening and closing speed.
7.2.11.2 Inspection and Testing
Inspection will be required on all aspects of the documentation in relation to any “as built”
drawings, applicable certification and test material certificates.
Individual testing of instruments will be required as well as pressure testing, NDT, leak testing as
stated in the particular specifications, data sheets. Following test and inspection shall be
included to the valves including the valves supplied by package equipment supplier as a
minimum:
 Visual Check
 Dimensional Check
 Hydro-Testing at 1.5 times the design pressure as per ASME B16.34
 Opening and closing time
 Open/close at least at 5 times to ensure smoothness of operations
 Seat leakage test
 Pneumatic leak test for actuators and tubing
7.2.11.3 Vendor Requirements
 The Vendor shall provide purchaser with at least 14 days‟ notice to witness test run in both
his shop and his sub-Vendor's shops.
 The Vendor shall provide calibration certificates for the test equipment for review by the
Purchaser prior to each test.
7.2.12 Spare Parts
7.2.12.1 Recommended Spares
 The Vendor shall provide in his tender the recommended spare Part list for all equipment
specified herein to cover the commissioning and start up, and the first two years of operation.
 The Vendor in the preparation of recommended spare part list shall follow equipment
manufacturer's recommendation. The Vendor shall note long lead items, and the availability
of shelf replacement part listings.
 All spare parts furnished by the Vendor shall be wrapped and packaged to preserve original
as new condition under normal conditions of storage anticipated at site. The same part shall
be properly tagged by stainless steel tags and coded so that later identification as to their
intended equipment usage will be facilitated. All items supplied shall be packaged separately

MADURA BD FIELD DEVELOPMENT - EPCI 18 of 20

CONTRACT NO : 332000002
 MADURA BD FIELD DEVELOPMENT – EPCI
PNEUMATIC ON-OFF VALVE AND MOTOR
OPERATED VALVE SPECIFICATION
DOC. NO. GMS-SPT-013 REV. 1

and clearly marked as “Spare Part" and shipped with the equipment in accordance with the
instruction from purchaser. Packing list shall be furnished complete and in detail so that part
can be handled without uncrating, if desired.
Recommended spares should take into account related factors of equipment reliability, effect of
equipment downtime upon production and safety, cost of parts and availability of equipment
service facilities.

8.0 DOCUMENTATION
COMPANY and CONTRACTOR shall review Vendor's drawings and documentation and make any
corrections before "Approved for Construction" drawings are issued. All modifications and changes
to any drawing, software or hardware configuration made during construction, installation, and start-
up shall be reflected on Vendor's final "As-Built" sets of documentation.

8.1 Approval Documentation

Vendor shall submit in writing a complete listing of the documentation planned and a schedule for
issuing the documents. This list shall be reviewed and agreed to by all parties.
Prior to the start of work, Vendor shall submit, as a minimum, the following documentation to
Company for review and approval in accordance with project requirements:
• General arrangement and outline drawings
• Control schematics, wiring diagrams
• Equipment and instrument data sheets
• Installation, operation and maintenance manuals
• Calculation Sheets

8.2 Final Documentation

Revised documentation shall be submitted after approval drawings have been received from
Company. Final (as-built) project data books shall be furnished, which shall include the following :
• General arrangement and outline drawings
• Control schematics and wiring diagrams
• Equipment and instrument data sheets
• Material certifications
• Installation, operation, and maintenance manuals
• Commissioning procedures
• Inspection reports
• Installation / interface drawings
• Test records
• Recommended spares for startup
• Recommended spares for two years operation
• Calculation Sheets

MADURA BD FIELD DEVELOPMENT - EPCI 19 of 20

CONTRACT NO : 332000002
 MADURA BD FIELD DEVELOPMENT – EPCI
PNEUMATIC ON-OFF VALVE AND MOTOR
OPERATED VALVE SPECIFICATION
DOC. NO. GMS-SPT-013 REV. 1

9.0 WEIGHT CONTROL

The Vendor shall exercise an active weight control system throughout the design, fabrication, and
assembly.
Vendor shall provide the location of the center-of-gravity of the supplied equipment.
Vendor shall provide "as-built" weighing of all equipment being furnished with complete description
of what is included in each weight.

MADURA BD FIELD DEVELOPMENT - EPCI 20 of 20

CONTRACT NO : 332000002