EXCEL EXPLORATION & PRODUCTION:DETAILED

ENGINEERING DESIGN OF 2 X 20,000 BARRELS CRUDE

STORAGE TANK

Doc Title: SPECIFICATION FOR SHUTDOWN VALVES

CODEFIDELITY TECHNICAL
SOLUTIONS

Doc. No.: Rev No.

CFTS-EXEP-INS-SPE-00000-05 R01 Page 1 of 31

SPECIFICATION FOR SHUTDOWN VALVES

R01 12/10/2023 Issued for Review C.O K.O T.O

REV DATE DESCRIPTION PREP’D BY CHK’D BY APPROVAL

TABLE OF CONTENTS
 Rev No.
R01 Page 2 of 31

1 INTRODUCTION .................................................................................................................................................... 4

1.1 GENERAL ...................................................................................................................................................................... 4

1.2 PURPOSE OF DOCUMENT ............................................................................................................................................... 5
1.3 ORDER OF PRECEDENCE ............................................................................................................................................... 5
1.4 NIGERIAN NATIONAL STANDARDS (LEGISLATIVE/REGULATORY REQUIREMENTS) .................................................... 5
1.5 AMERICAN PETROLEUM INSTITUTE (API) ............................................................................................................... 5
1.6 AMERICAN NATIONAL STANDARD INSTITUTE (ANSI) ............................................................................................. 6
1.7 AMERICAN SOCIETY FOR TESTING & MATERIALS (ASTM) ..................................................................................... 7
1.8 AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) ..................................................................................... 7
1.9 NATIONAL ASSOCIATION OF CORROSION ENGINEERS (NACE) ................................................................................ 7
1.10 ABBREVIATIONS ...................................................................................................................................................... 8
1.11 REFERENCE DOCUMENTS .......................................................................................................................................... 9

2 UNITS ................................................................................................................................................................... 10

2.1 SITE CONDITIONS .................................................................................................................................................... 11

3 SCOPE ................................................................................................................................................................... 12

4 TYPES OF VALVES AND THEIR APPLICATION ............................................................................................ 12

4.1 GENERAL .................................................................................................................................................................... 12

5 SHUTDOWN VALVES ............................................................................................................................................. 13

5.1 BALL VALVES ............................................................................................................................................................ 13

5.2 BUTTERFLY VALVES .................................................................................................................................................. 13
5.3 SOLENOID VALVES .................................................................................................................................................... 14

6 BODY CONSTRUCTION AND MATERIALS ......................................................................................................... 14

6.1 GENERAL .................................................................................................................................................................... 14

6.2 BODY SIZE ................................................................................................................................................................ 14
6.3 END CONNECTION ...................................................................................................................................................... 15
6.4 FACE-TO-FACE DIMENSIONS.................................................................................................................................... 15
6.5 MATERIALS ................................................................................................................................................................ 15
6.6 STUFFING BOX AND PACKING ................................................................................................................................... 15
6.7 GENERAL .................................................................................................................................................................... 15
6.8 GASKETS .................................................................................................................................................................... 16

7 VALVE TRIM AND SEAT RING ......................................................................................................................... 16

7.1 SEAT LEAKAGE AND FLOW DIRECTION ..................................................................................................................... 16

7.2 CONSTRUCTION .......................................................................................................................................................... 16
7.3 MATERIALS ................................................................................................................................................................ 16

8 VALVE ACTUATOR ............................................................................................................................................... 17

8.1 GENERAL .................................................................................................................................................................... 17

8.2 ACTUATOR MATERIAL ................................................................................................................................................ 21
8.3 STROKING TIME ........................................................................................................................................................ 21
8.4 ACTUATOR COLOUR CODING ...................................................................................................................................... 22

9 ACCESSORIES...................................................................................................................................................... 23

9.1 HAND WHEELS ............................................................................................................................................................ 23

 Rev No.
R01 Page 3 of 31

9.2 LOCK-UP VALVES ...................................................................................................................................................... 23

9.3 LIMIT SWITCHES ...................................................................................................................................................... 23
9.4 AIR LUBRICATORS .................................................................................................................................................... 24
9.5 SOLENOID VALVES .................................................................................................................................................... 24
9.6 FILTER REGULATORS ................................................................................................................................................ 25
9.7 FILTERS .................................................................................................................................................................... 26
9.8 VOLUME BOOSTERS .................................................................................................................................................... 26

10 VALVE IDENTIFICATION.............................................................................................................................. 27

11 INSPECTION AND TESTING ......................................................................................................................... 28

11.1 EXTENT ................................................................................................................................................................. 28

11.2 HYDROSTATIC TEST .............................................................................................................................................. 28
11.3 FUNCTIONAL TEST ................................................................................................................................................ 29
11.4 SEAT LEAKAGE TEST............................................................................................................................................ 29
11.5 MATERIALS AND INSPECTION CERTIFICATION .................................................................................... 29

12 WITNESSING BY ENGINEER/ COMPANY ..................................................................................................... 30

13 PROTECTION AND PACKAGING..................................................................................................................... 30

14 DOCUMENTATION ............................................................................................................................................. 30
 Rev No.
R01 Page 4 of 31

1 INTRODUCTION

1.1 General
Designated within the realm of the Federal Government of Nigeria
initiative and in alignment with the regulations set forth by the
petroleum (Amendment) Decree No. 23 of 1996, the Eremor field
emerges as one among the collection of twenty-four marginal fields
entrusted to indigenous companies engaged in oil exploration and
production. Excel Exploration and Production, a Nigerian Company
operating within the upstream domain of the oil and gas industry,
was granted ownership of this field. Nestled in the onshore swamp
expanse of Bayelsa state, specifically within Shell's OML 46 at
the South Forcados region, the Eremor field occupies a pivotal
position. It is positioned 4 kilometres to the north of the
Tunu/Kanbo field and approximately 70 kilometres to the south of
Warri. Encompassing a span of roughly 64.7 square kilometres, this
field remains a noteworthy presence in the area. Excel E&P Facility
is located at Eremor, near Ekeremor community in Ekeremor Local
Government Area of Bayelsa State, Nigeria.

Excel Exploration and Production Company Limited, the Client, seek

increase crude oil storage capability within the Eremor Facility.
Consequently 2 x 20,000 Barrels Crude Oil Storage tank is to be
built within the Eremor Facility.

CodeFidelity Technical Solutions has been contracted to carry out

the required detailed engineering design for the tanks.
 Rev No.
R01 Page 5 of 31

1.2 Purpose of Document

The purpose of this document is to outline General Specification
For Instruments that serves as a basis, guiding the engineering of
the 2 x 20,000 barrels storage tanks.

1.3 Order of Precedence

The following order of precedence shall be applied:

1. Nigerian National Standards (Legislative/Regulatory

requirements)

2. Chorus Energy Limited Specifications

3. International Standards

1.4 Nigerian National Standards (Legislative/Regulatory Requirements)

The Mineral Oils (Safety) Regulations of the Federal Republic of
Nigeria.

The Oil Pipelines Act (1990) Supplement to the Nigerian Oil and
Gas Pipelines Regulations (1995).

1.5 American Petroleum Institute (API)

API 5L Specification for Line Pipe

API 6D Specification for Pipeline Valves

API 12J Specification Oil & Gas Separators

API 14E Recommended practice for Design & Installation of

Offshore Production Platform piping systems.

API 14C Recommended practice for Analysis, Design,

Installation and Testing of Basic Surface Safety
system for Offshore Production Platforms.

API 520 Sizing, Selection and Installation of Pressure

Relieving Devices in Refineries

API 526 Flanged Steel Safety Relieving Valves.

 Rev No.
R01 Page 6 of 31

API 521 Guide for Pressure Relieving and Depressurization

Systems.

API 598 Valve Inspection and Testing

API 599 Metal Plug Valves—Flanged, Threaded and Welding

Ends

API 600 Steel Gate Valves - Flanged and Butt-welding

Ends, Bolted Bonnets.

API 602 Gate, Globe, and Check Valves for Sizes DN 100
(NPS 4) and Smaller for the Petroleum and Natural
Gas Industries.

API 607 Fire Test for Quarter-turn Valves and Valves

Equipped with Nonmetallic Seats.

API 609 Butterfly Valves: Double-flanged, Lug- and Wafer-

type.

API 650 Welded Tanks for Oil Storage

AP1 2000 Venting Atmospheric and Low-pressure Storage

Tanks

1.6 American National Standard Institute (ANSI)

ANSI B 16.5 Specification for Steel Pipe Flanges and Flanged
Fittings

ANSI B 16.9 Steel Butt Weld Fittings

ANSI B 16.25 Butt Welding Ends

ANSI B 31.3 Chemical Plants and Petroleum Refinery Piping

ANSI B 31.4 Pipeline Transmission Systems for Liquid

Hydrocarbons and Other Liquids
 Rev No.
R01 Page 7 of 31

1.7 American Society for Testing & Materials (ASTM)

ASTM A105 Carbon Steel Forgings for Piping Components

ASTM A106 Standard Specification for Seamless Carbon Steel

Pipe for High-Temperature Service

ASTM A333 Carbon Steel Forgings for Piping Components

ASTM A 193 Alloy Steel and Stainless Steel

1.8 American Society of Mechanical Engineers (ASME)

ASME VIII Boiler and Pressure Vessel Code

ASME SEC IX Welding Procedure and performance qualification

1.9 National Association of Corrosion Engineers (NACE)

MR-01-75 Sulphide Stress Cracking Resistant Metallic
Material for Oil Field Equipment
 Rev No.
R01 Page 8 of 31

1.10 Abbreviations
The Acronyms and abbreviations used within this document are
listed below:

Abbreviation Description

C & E Cause & Effect

ESD/ESDV Emergency Shutdown/ Emergency Shutdown

Valve

ft Feet/foot

F & G Fire & Gas

GA General Arrangement

I/O Input & Output

KBPD Thousand Barrel per day

MMSCFD Million Standard Cubic Feet per Day

MTO Material Take Off

PFD Process Flow Diagram

P&ID Piping and Instrumentation Diagram

PSIG Gauge Pressure in pound per square inch

ROW Right of Way

XCP Independent control panel

SDV Shutdown Valve

 Rev No.
R01 Page 9 of 31

1.11 Reference Documents

S/N Document Number Title

1. CFTS-EXEP-PRO-RPT-00000-01 SITE VSIST REPORT
2. CFTS-EXEP-PRO-RPT-00000-02 DESIGN BASIS
3. CFTS-EXEP-INS-PHI-00000-02 CONTROL & SAFEGUARDING PHILOSOPHY
4. CFTS-EXEP-PRO-DTL-00000-08 PIPING AND INSTRUMENTATION DIAGRAMS (P&IDS)
5. CFTS-EXEP-INS-SPE-00000-01 GENERAL SPECIFICATION FOR INSTRUMENTS
 Rev No. Page 10 of
R01 31

2 UNITS

The units shown below (Customary/Imperial units in general) shall

be used as the main design units and all values quoted shall be in
these units. For clarity, alternative unit values are indicated in
the brackets only, after the design unit, when it is believed
desirable. The size of the unit shall be appropriate to the value
being measured.

Table 2-1: Units of Measurement

Description Unit

Nominal pipe diameters Inches (mm)

wall thickness Inches (mm)

Length ft (mm or m or km)

Area ft²(m2)

Liquid Volume ft³(m3)

Volumetric Oil Flow Rate MBPD

Standard Gas Volumetric MMSCFD (m3)

Flow Rate

Velocity ft/s (m/s)

Density lb/ft³(Kg/m3)

Pressure Psig (Barg)

Valve Size Inches (mm)

Viscosity cP
 Rev No. Page 11 of
R01 31

2.1 Site Conditions

Site conditions are assumed as shown below:

 Ambient Temperature Range 20 - 39°C

 Wind Velocity 0-80 mph

 Relative Humidity - Maximum 100%

 Rev No. Page 12 of
R01 31

3 Scope

This Specification, together with all reference documentation,

defines the minimum technical requirements for the sizing, selection,
design, manufacture, test, supply, install,documentation and
preparation for shipment of Shutdown Valves for Development Project.

The CONTRACTOR shall use this specification together with other

detailed instrument specifications, datasheets supplied to establish
the detail design and final selection of Valves in their proposal.

This specification shall not be considered all-inclusive. The VENDOR

shall submit full technical details of their standard equipment,
which meet the requirements herein.

Aspects of the requirements, which cannot be met, shall be identified

and variances explained

4 TYPES OF VALVES AND THEIR APPLICATION

4.1 General
Unless otherwise specified in the instrument data sheets or dictated
by its application, the selection of a type of valve should be in the
following order of preference:

• Ball valve;

• Butterfly valve;

Design shall be in accordance with API Standard 6D for pipeline

shutdown valves and to API 6D or BS 5351 for non pipeline shutdown
valves as specified in the requisition.

The materials and rating of valves shall be in accordance with the

piping class. Valves specified to BS 5351 are acceptable in the
following sizes ANSI Class Size:

• 150, DN 250 and below;

• 300, DN 40 and below

of stainless steel and be fixed with screws or rivets.

Blow down valves noise shall be less than 110 dB at a 3 m distance.
Cadmium plating or galvanising shall not be used for any component of
the valves assembly or its accessories.
 Rev No. Page 13 of
R01 31

5 Shutdown Valves

Unless otherwise required, emergency shut-off valves shall be

designed and installed as “flow-tending-to-close”.
ESD and On / Off valves materials of construction, valve design, and
standards shall be selected in accordance with Piping Material
Specification 12-MGDP-P-1000. The exception is the valve stem
material, which shall be selected to withstand the maximum
torque / thrust of the actuator (Refer to section 6.0), and
consideration given to the frequency of valve use.

5.1 Ball Valves

Ball valves shall be considered for on-off service.
Ball valves shall comply with the piping class. The type of actuator
shall be as per datasheet or as specified by the COMPANY.
Ball valves for use in erosive (e.g. slurry) service etc. should be
equipped with a scraper type of seat construction.
Ball valves shall not be selected for throttling service without the
approval of the COMPANY.
Unless equipped with a special trim, i.e. anti-cavitation or low-
noise design, care should be taken with the selection of ball valves
for high differential pressures.

5.2 Butterfly Valves

Butterfly valves shall be considered for the following circumstances
subject to COMPANY approval:
• If the required size (usually due to a high flow rate with a low
pressure drop)would make it economically attractive;
• If it is impossible to use eccentric plug/ segmented ball;
"High performance butterfly valves" can be used for high temperatures
and high differential pressures, with Class V or Class VI shut-off
performance application.

Spring-opening butterfly valves should not be of the wafer or lug

type but should have a valve body (in order to allow removal of the
valve from the piping system). If a wafer or lug type butterfly valve
is used (shall only be considered for non-hydrocarbon service), a
removal of the valve. The provision of a hand wheel shall be subject
to the approval of the COMPANY.

Where butterfly valves are installed in vertical piping, it shall be

arranged so that the diaphragm actuator remains clear of the piping.
 Rev No. Page 14 of
R01 31

5.3 Solenoid Valves

Apart from their use in instrument air signal lines, solenoid valves
may only be considered for on-off control in hydraulic utility
services, such as hydraulic control systems for remotely operated
valves and wellhead control units as required by Company.
Solenoid-operated valves shall, unless otherwise specified, be
normally closed valves suitable for continuous operation at the
supply voltage.

6 BODY CONSTRUCTION AND MATERIALS

6.1 General
Body construction may be split body with flanged ends or all welded
body as specified on the requisition. Split body design shall be
utilised in sizes of DN 600 ANSI class 900 and below to facilitate
shop maintenance. Top entry valves shall not be specified as insitu
maintenance is not a requirement. Top entry valves may, however, be
accepted should they be offered and are commercially attractive. All
valves shall be flanged end type.

Shutdown valves, other than wafer/wafer lug type butterfly valves,

shall be provided with flanges.
Wafer type valves and lug flanges shall only be considered for non
hydrocarbon service.
Valve bonnets shall be of bolted construction with fully retained
gaskets.
For valves DN 450 and above, VENDOR shall clearly state in his
proposal the maximum allowable bending moment which may be applied to
the valve body.
Both metal and soft seated valves shall be to a fire-tested design.
Copies of applicable certification shall be provided with the bid for
the valves.
The materials of construction for all components of the valve shall
be clearly listed in the proposal.

6.2 Body Size

Emergency shut-off valves shall be sized for the process conditions,
and the pressure drop shall be kept to a minimum.
For ball valves, full bore valve is the first choice, reduced bore
valve may be considered only if approved by the COMPANY
 Rev No. Page 15 of
R01 31

6.3 End Connection

The ASME rating class of flanges shall be in accordance with the
piping class unless otherwise specified. Flanges shall be in
accordance with ASME B16.5 or ASME B16.47,as applicable.
The flange gasket contact surface finish shall be in accordance with
ASME B16.5.Welding of flanges is not acceptable.

6.4 Face-to-Face Dimensions

The face-to-face dimensions of lug and wafer type butterfly valves
shall be in accordance with BS 5155.
The face-to-face dimensions of flanged rotary valves (segmented ball)
shall be in accordance with either API 6D or IEC 60534-3-1.

6.5 Materials
The material selection of the body (including bonnet and/or bottom
flange), external bolts, studs and nuts, etc. shall be in accordance
with the valve data sheet and piping material specification.
All valve materials for sour service shall conform to the latest
edition of NACE MR-0175 / ISO15156 standards.

6.6 Stuffing Box and Packing

6.7 General
The packing materials shall be:
• PTFE-based for temperatures at the packing below 200°C;
• Graphite-based, for temperatures at the packing between 200°C and
600°C.
Packing shall not contain asbestos.
Air cylinder and piston material shall be such that no external
lubrication supply is necessary.
Depending upon the design of the valve, an extended bonnet may be
required to keep the temperature at the stuffing box at an acceptable
value for the applied packing.
An extended bonnet may also be required if the operating differential
pressure across the valve could otherwise cause freezing of the
stuffing box/packing and/or ice formation
on the yoke.
The stuffing box shall be provided with an adjustable bolted gland
flange and gland follower. The valve gland shall be properly adjusted
by the valve VENDOR. If, for technical reasons, the valves are
delivered with a loose gland, this shall be clearly
indicated on the appropriate valve with a warning sign.
 Rev No. Page 16 of
R01 31

6.8 Gaskets
Unless otherwise dictated by the process conditions and piping
specification, the gasket material shall be AISI 316 type stainless
steel, graphite filled.
The filler material shall be expanded graphite with the following
specification:
• Maximum 1% ash content;
• Maximum 50 mg/kg chloride content;
• Density range 0.7 to 1.8 g/cm3.
Other types of gasket shall be subject to the approval of the
COMPANY.

7 VALVE TRIM AND SEAT RING

7.1 Seat Leakage and Flow Direction

Unless otherwise required, on-off and emergency shut-off valves
should be specified and installed as "fail-to-close".
The direction of the shut-off requirement (for one or both
directions) shall be as indicated on the relevant P&ID’S.
Balanced-type single-seated control valves of the pilot-operated type
shall not be used as TSO valves.
For seat leakage testing, reference is made to (9.5).

7.2 Construction
The plug and the seat ring(s) shall be of the easy/quick replaceable
type.
Special attention shall be paid to fixing of the seat ring in order
to prevent loosening due to vibration. Adhesive compounds shall not
be used for the locking of seat rings.
If required, the valve stem part that is exposed to the surrounding
atmosphere shall be completely covered by a protection bellows. This
protection bellows shall be of a material, which is resistant to
corrosion by the product and the environment.
Lifting lugs shall be provided for valves 3” in size and larger.

7.3 Materials
The shutdown valve trim shall be corrosion resistant and of the grade
specified in the data sheets. For fluids that become corrosive when
in contact with the atmosphere,
suitable valve stem and trim materials shall be considered or
precautions shall be taken to prevent contact with air.
 Rev No. Page 17 of
R01 31

Where soft (resilient) inserts are required for meeting the specified
leakage rate, the selection shall be based on their suitability for
the specified process conditions. The resilient insert shall be
properly clamped between metal parts and/or locked in position
to prevent blowout in the closed position.
Hardened, (e.g. Stellite or Colmonoy-coated) or solid Stellite
closure members and seat rings shall be selected for the following
applications:
• Erosive services, cavitating services and choked flow;
• Wet gas with a pressure drop greater than 5 bar;
• Other services in which the pressure drop is greater than 20 bar at
temperatures above 300°C.
For economic reasons, and if suitable for the specified process
conditions, hardened AISI 440C type stainless steel (hardness
approximately 550 BHN) may be considered as
trim material if approved by the COMPANY.

8 VALVE ACTUATOR

8.1 General
The actuator shall be suitable for instrument air unless otherwise
specified in the requisition.
The actuator shall function properly under the minimum, normal and
maximum instrument air supply pressures and process conditions as
specified in the requisition.
The following general requirements shall be applicable:
The valve assemblies, including all ancillaries, shall have a minimum
nominal design life of 20 years based on VENDOR's recommended
maintenance procedures being followed during this period. For all
actuated valves this shall correspond to a nominal minimum
design limit of 1000 cycles.
Materials of construction shall be suitable for achieving the above
design life in a corrosive offshore or coastal environment. VENDOR
shall specify in his quotation, materials of construction for all key
components of the actuator assembly and ancillary
equipment.
Aluminium components shall not be specified for actuators or
ancillary equipment.
The actuator type shall be as specified in the requisition. In
general actuator type selection shall be based on the following order
of preference.
Shutdown Valves and Blowdown Valves. (SDV's and BDV's) shall
preferably utilise pneumatic, single acting, spring return actuators.
 Rev No. Page 18 of
R01 31

Where space or torque limitations preclude the use of this type of

actuator the following types may be specified.

 Hydraulic, single acting, spring-return;

 Hydraulic, double acting;
 Pneumatic, double acting.

On loss of holding signal, or on loss of pneumatic/hydraulic

pressure, SDV's shall revert to the closed position and BDV's shall
revert to the open position.
Accumulators for double acting actuators in SDV or BDV service shall
be close coupled to the actuator. Alternatively the accumulator
system may be shipped loose and located in a nonvulnerable area
remote from the actuator providing that hydraulic/pneumatic
supply and return lines to and from the actuator are suitably
protected against fire/-explosion damage.
Actuators shall be sized to provide the following torque value based
on the requirements of a new value, at all points of its operating
cycle, from fully open to fully closed and viceversa.
The required actuator torque shall be a minimum of 1.25 times the
manufacturers maximum specified torque value at a pressure
differential across the valve-equal to the
full ambient temperature rated pressure of the valve. The valve
torques shall be based on infrequent usage of approximately one cycle
every 3 months.
For SDV's, the above actuator torque shall be based on the specified
minimum pneumatic or hydraulic supply pressure.
For all valves the valve stem shall be sized such that it can not be
subjected to torsional stresses in excess of that permitted by the
valve manufacturer with the pneumatic/
hydraulic supply at its specified maximum pressure. These criteria
shall also be applicable if the MAWP of the actuator body is below
the maximum stated air supply pressure.
The valve assembly shall be capable of being orientated in any
direction with no external supports, Mounting details shall be such
that no undue stresses are imparted to the
actuator or valve shaft/body regardless of orientation.
Pneumatic/hydraulic actuator bodies shall be of integral or all
flanged/bolted construction. The use of pressure containing external
tie bar construction shall not be permitted.
For pneumatic and hydraulic actuators an adjustable restriction
device shall be provided in the supply line to the actuator to enable
the opening line to be adjusted.
All actuators and ancillary equipment shall have a minimum ingress
protection to IEC 60529, IP 65.
 Rev No. Page 19 of
R01 31

The actual bench setting (spring range) shall be indicated on the

valve tag plate.
Actuators shall be designed for a minimum instrument air pressure of
3.5 bar (g), unless otherwise required. Actuators requiring an
instrument air supply pressure above 3.5 bar(g) shall not be used
unless approved by the COMPANY.

The piston-type actuator, if specified, should be of the spring-

opposed diaphragm or of the spring-opposed short-stroke type.
Long-stroke springless piston actuators shall not be used.
To prevent tampering, the rotating linkages between a butterfly valve
and its actuator shall be of the integral type, enclosed in a
protective metal housing.
Cylinder actuators shall be provided with adjustable end-limit travel
stops in both directions. Bolt adjustment type limit stops shall be
fitted with a locking facility, e.g. a locking nut, to prevent
tampering. The construction shall be leak-tight, with seal gaskets.
Piston or cylinder actuators shall have O-ring sealing and shall be
designed to minimize shaft and piston friction.
Actuators shall be equipped with a direct-coupled adjustable travel
or position indicator for local status indication. The position shall
be indicated by a permanent mark on a reversible scale with the words
'open' and 'shut' at the travel limits, or by unambiguous symbols.
The following additional requirements are applicable for pneumatic
actuators:
• Pilot-operated valves for SDV's and BDV's shall, unless otherwise
specified, be normally closed valves suitable for a-maximum supply
and pilot pressure of 10 barg. Body material shall be 316SS and the
valve shall be provided with a manual reset facility.
• Pilot and solenoid operated valves for double acting actuators
shall be generally as described above but shall be five port 4-way
valves capable of alternately pressurising and venting each face of
the power piston to open/close the valve as applicable.
• Pneumatic tube and compression fittings shall be 316L Stainless
Steel and shall be 10 mm OD x 1.50 mm wall thickness unless specified
otherwise in the purchase requisition. Fittings shall be double
ferrule type Swagelok or equal.
• Unless specified to the contrary, accumulators for double acting
actuators for SDV's shall be sized for three (3) strokes of the valve
based on the specified normal and minimum pneumatic supply pressure.
• Pneumatic actuators shall be configured such that they will hold
open /closed against spring pressure at a minimum pressure of 3.5
barg.
The following additional requirements are applicable for hydraulic
actuators:
 Rev No. Page 20 of
R01 31

• Hydraulic actuators may be double acting or hydraulic opening

spring return type. In this context rotary vane type actuators shall
be considered acceptable.
• The design of the valve hydraulic system shall be generally in
accordance with PTS 31.36.10.30.

VENDOR may propose variations to-the PTS system configuration

provided that these are highlighted in his bid for the systems with
sufficient information to enable their acceptability to be evaluated.
• Hydraulic pumps may be electrically or pneumatically operated. The
pumps shall be provided with a manual stop/start facility and an auto
start/stop facility to reestablish system pressure in the event that
this should fall below an acceptable level.
• The required capacity of the system accumulators shall be based on
the pressure at which the hydraulic pumps auto start.
• Unless otherwise stated in the purchase requisition one hydraulic
hand pump shall be provided per system. The system shall be
configured such that it shall not be possible to manually open the
valve whilst the shutdown relay is in a deenergised
state. No means of bypassing the shutdown system shall be provided.
• The capacity of the hydraulic accumulators for central hydraulic
systems shall be sufficient to provide three (3) strokes of the
largest actuator connected to the system plus two (2) strokes of all
other connected actuators. For a single valve
system the accumulator(s) shall be sized for three (3) strokes of the
valve.
• All submissions shall include details of hydraulic pressures at
pump start/stop
points and upon completion of the specified number of valve strokes
with the pressurising pumps in-operative .
6.2 Shutdown Valve Actuator
In addition to the general requirements for the actuators,all ESD
valves, and as specified On / Off valves, shall be fitted with fail
safe, air driven, spring opposed,piston-type actuators. The use of
any other type of actuator must first have COMPANY approval. An
integral field ‘Open/Close’ indicator shall be included. This shall
preferably be mounted on top of the actuator. Actuators shall be
attached to the valve stem as per ISO 5211. ESD Valves shall not be
fitted with hand wheels unless specified.
The yoke shall be of the open type to allow access for adjustment of
the packing gland follower.
The actuator spring shall be fully enclosed in a metal housing and
treated to resist atmospheric corrosion.
The assembled actuator shall be designed to withstand (without
damage) the
 Rev No. Page 21 of
R01 31

mechanical design pressure of the Instrument Air System 10 barg. In

order to facilitate proper installation of the actuator, the required
mounting facility on the valves shall be
designed and manufactured in consultation with the Supplier of the
valve actuator.
The design thrust or torque for actuator selection and all drive
train calculations shall be at least twice the breakaway thrust or
torque. However, when the valve is “running”, a
minimum factor of safety of 1.25 times differential is obligatory
between the maximum torque / thrust required to cycle the valve (with
maximum differential pressure across the
valve) and the output torque / thrust developed by the actuator, with
air driven stroke of 3.5 barg, and spring driven stroke.

Tensile stresses in the drive train components, including stem

extensions, shall not exceed 67% of the specified minimum yield
strength (SMYS) when delivering the design
torque. Shear, torsion, and bearing stresses shall not exceed the
limits specified in ASME Code Section VIII, Division 2, Part AD-132.
If fireproofing has to be applied, accessories for ESD valves and
actuators are protected from fireby installation inside protective
local enclosures. The enclosures shall be rated for 30-minute fire
rating without increasing internal temperature above the maximum
allowable limit for the actuator and accessories. The box enclosure
design shall have windows and apertures to provide visibility and
access to accessories. The aperture shall be designed in such a way
that accessories can easily be removable through this
without removing the enclosure. In particular, the valve travel
indicator shall be extended outside enclosure.

8.2 Actuator Material

ESD valves actuators shall be made preferably of steel, aluminum
actuators shall not be used.

8.3 Stroking Time

Unless other stroking times are indicated in the requisition, the
following stroking times for both directions are required:
• 1 second per inch of nominal size with a maximum of 45 seconds.
If faster stroking times are required, high capacity valve
positioners should be considered. If these are not available, then
additional boosters or quick-exhaust valves
shall be installed. Valves used for on/off service (e.g. ESD valves,
or control valves with a trip function)
 Rev No. Page 22 of
R01 31

shall have a stroking time as indicated on the P&ID’S or in the

requisition or instrument data sheet.
If air pressure is used to close the valve under emergency conditions
or to assist the spring force, the size of the air signal line and
fittings and the air capacity of the accessories shall be designed to
ensure the specified stroking time.
The effect of stroking time on the pressure build-up in liquid-filled
lines (hydraulic shock or water hammer) should be checked.
Similarly, to prevent shock-loading of process equipment downstream
of fail-closed shutoff valves, a special design may be required to
ensure controlled (re-)opening of these valves.
The stroking times are applicable to the valve with accessories, e.g.
solenoid valves, etc.

8.4 Actuator Colour Coding

The colour of the actuator shall be in accordance with the painting
specification number 12-MGDP-P-1005 unless otherwise specified in the
requisition or by COMPANY. To for spring closing valves and green for
spring opening valves), as specified in the requisition.
 Rev No. Page 23 of
R01 31

9 ACCESSORIES

9.1 Hand Wheels

Shutdown valves shall not be provided with a hand wheel unless shown
on the P&ID’s.
If a hand wheel is required, the following shall apply:
• The hand wheel shall be of an all-metal design;
• The hand wheel shall be provided with position indicators;
• The operating force, under maximum design conditions, shall not
exceed 350 N on the rim of the hand wheel;
• The changeover from actuator operation to hand wheel operation
shall be possible in all stem positions;
• The hand wheel shall be of lockable type.

9.2 Lock-up Valves

Air lock-up valves shall be specified for the following applications:
• All shut-off valves requiring an air supply pressure higher than
the guaranteed minimum instrument air pressure.
The lock-up valves shall have a bolt adjustment provided with a
locking facility, e.g. a locking nut, to prevent unintentional
adjustments.
The lock-up valves shall be set 0.5 bar above the required valve air
supply pressure unless some other set value is required for a
particular actuator.
For lock-up valves fitted on valves operated by a solenoid valve,
this solenoid valve shall be installed between the lock-up valve and
the actuator.

9.3 Limit Switches

"Open" and/or "close" limit switches shall be fitted only if shown on
the P&ID’s. When specified in the purchase requisition, the
valve/actuator assembly shall be provided with electrical limit
switches which will indicate when the valve is either in the
fully open or fully closed position. If fitted, the external linkage
between the actuator stem or rotary spindle and the initiator shall
be protected against unintentional damage.
Protection shall be to IEC-60529, IP65 and the switches shall be
suitable for inclusion in an intrinsically safe circuit. Proximity
switches shall be configured such that metal is
detected when the end position is reached. Mechanically operated
switches shall be configured such that the contacts are open when the
valve is in the appropriate fully open or fully closed position and
closed when the valve is stroking.
 Rev No. Page 24 of
R01 31

Limit switches shall be proximity type (preferred) or mechanically

operated hermetically sealed rated for 0.5A at 24V DC and shall
terminate in an attached junction box; alternatively, the protection
box and the junction box may be combined into one box. The switches
shall be SPDT and shall utilise a 20mm ISO single electrical entry.
Proximity switches shall be of dry-contact type. NAMUR type switches
are not acceptable. The
Junction boxes shall be suitable for the electrical hazardous area
classification in which they are located. If not armoured, the flying
leads shall be protected by a flexible conduit.
Proximity switches shall be adjustable and shall function
autonomously, e.g. one switch for the "fully open" position and a
separate switch for the "fully closed" position.
The combination of proximitor and proximitor circuit shall be of
fail-safe design.
The mounting instructions supplied by the limit switch VENDOR shall
be followed by the valve VENDOR. The limit switches shall be properly
adjusted by the valve VENDOR.

9.4 Air Lubricators

It is required that air cylinder and piston material shall be such
that no external lubrication supply is necessary. However if the
application demands air lubricators (if approved by the COMPANY)
shall be of the oil-mist type and the oil flow shall be
externally adjustable. The oil buffer capacity shall be sufficient
for continuous operation for one month.
In addition, the lubricator shall have facilities for oil refilling
under pressure, shall have oil level indication and shall be suitable
for installing on a mounting plate.
Where air lubricators are used for valves operated by a solenoid
valve, the lubricator shall be installed upstream of the solenoid
valve.
Air lubricators shall be considered for pneumatic long-stroke
cylinder actuators. Spherical glass (bowl type) air lubricators shall
not be used.

9.5 Solenoid Valves

For emergency shut-off valves, the solenoid valve shall be installed
directly on the valve actuator.
Solenoid valves should be direct-operated; the use of pilot-operated
solenoid valves
 Rev No. Page 25 of
R01 31

shall be subject to the approval of the COMPANY.

The capability of the solenoid valve (e.g. capacity, pressure rating)
shall be checked against the instrument air requirement of the
particular actuator.
Solenoid valves shall be 24VDC, low wattage (6 watts) with class F
insulation. Body shall be 316 SS. Body rating shall be a minimum of
10 barg; a manual reset facility shall be provided, solenoid valve
for SIS loop shall be SIL-3 certified. Flying leads are not
acceptable. Solenoid valve shall be provided screw type terminals
with M20 cable entry for electrical connections.

Electrical certification shall be as per specified in the datasheet

but minimum EEx 'i' llA T3 with protection to IP 65. To prevent high
voltage induction, solenoid valves operating on direct current shall
be provided with reverse diodes.
The solenoid valves shall be provided with a disc and/or seat of
resilient material to achieve TSO. The air passages in the solenoid
valves shall be large enough to achieve the opening or closing time
of the valve as specified. If this would lead to unrealistically
large passages and consequently high power consumption of the
solenoid valve, consideration should be given to the use of quick-
exhaust valves.
The minimum port size in the solenoid valve shall be stated by the
solenoid valve VENDOR and this shall be taken into account in the
stroking time calculations.Solenoid
valves shall be not be supplied with exhaust port protectors but, to
prevent plugging,shall be provided with a piece of tubing bent
downwards, with the end cut off at an angle
of 45 degrees. Ambient temperatures, including the effects of direct
sunlight, shall be specified and the solenoid valve selected
accordingly.

9.6 Filter Regulators

If the maximum air supply pressure is greater than the operating
pressure of the actuator or its accessories, or if the valve
positioner needs a regulated air pressure, then an air
filter regulator shall be installed in the instrument air supply
line. The make of filter regulator shall be as specified in the
requisition.
The air filter regulators shall be of the reducing-relief valve type,
with drainage facility and bolt adjustment provided with a locking
facility, e.g. a locking nut, to prevent tampering. Air filter
regulator shall be 316SS body with 316SS output gauge.
The air filter cartridges shall be of the rigid structure type to
resist channelling, rupturing,
 Rev No. Page 26 of
R01 31

shrinkage or distortion and shall have a maximum mesh size of 40 mm.

The capability, e.g. output capacity and required spring range, of
the filter-regulator shall be checked against the instrument air
requirement of the particular actuator or pneumatic instrument.
Glass (bowl-type) filter regulators shall not be used.
Filter regulators shall be mounted vertically so that they are self-
draining. If the actuator is capable of withstanding full instrument
air pressure (specified maximum
design condition of the instrument air supply system), no regulator
shall be installed, only a filter.

9.7 Filters
If a filter regulator is not installed an air filter shall be
installed in the instrument air supply line to the valve. The air
filter shall be provided with a manual drainage facility and a filter
cartridge of the rigid structure type, to resist channeling,
rupturing, shrinkage or distortion, and having a maximum mesh size of
40 micron. Glass (bowl type) filters shall not be used.
Filters shall be mounted vertically so that they are self-draining.

9.8 Volume Boosters

Volume boosters shall only be provided if needed to achieve the
specified stroking times. Volume boosters for pneumatic actuators
shall be of the high capacity type with fast throttling to control
the required capacity.
 Rev No. Page 27 of
R01 31

10 VALVE IDENTIFICATION

The valve shall be provided with a standard stainless steel

identification plate. At least the following information shall be
clearly stamped on the plate:
• Manufacturer's name or trademark.
• Manufacturer's model/type number (valve and actuator).
• Manufacturer's serial number.
• Body pressure rating.
• Size (body and trim/ Cv value).
• Material (body and trim).
• Type of plug (characteristic).
• Bench setting or spring range.
• Action on air supply and/or signal failure.
In addition, each valve shall be provided with a stainless steel tag
plate, which shall be
fixed to the valve with a stainless steel wire. This plate shall be
marked with the COMPANY's tag number as stated in the requisition.
Valves shall be marked in accordance with the applicable design code.
The direction of flow, the valve body rating, the body material and,
where applicable, the TSO direction(s) shall be clearly indicated by
a permanent mark cast in or stamped on the valve body, not painted.
The valve tag number shall be stamped on the valve body or flange if
the identification plate is attached to the actuator.
Warning plates shall be fixed by screws or rivets.
 Rev No. Page 28 of
R01 31

11 INSPECTION AND TESTING

11.1 Extent
The VENDOR shall perform the following inspections and tests (see
Note 1):

Notes:
1 The specified extent and acceptance criteria shall be in accordance
with the VENDOR's standard where more frequent or stringent.
2 The number of valves sampled shall be subject to the approval of
the COMPANY.
3 The selected valves for each test shall be listed by the VENDOR and
approved by the COMPANY.
4 Inspection and testing shall include accessories if part of the
supply.
5 The test results shall be made available to the COMPANY as part of
the package of final certified documents and drawings.
6 Hydrogen service means all process conditions with a hydrogen
partial pressure greater than 7 bar (abs)
Dimensional and Flange Face Finish Check The face-to-face dimensions
of flanged body valves shall be as given in the relevant
standard refer section 4.4. All dimensions (including overall height)
shall be as shown on the VENDOR's drawings.The flange face finish
shall be checked.

11.2 Hydrostatic Test

Hydrostatic testing shall be in accordance with API 6D at test
pressure or better, with the
test duration as follows:
Valve size Test Duration
 Rev No. Page 29 of
R01 31

≤ 2” 1 minute
3” to 8” 2 minutes
≥ 10” 3 minutes

11.3 Functional Test

The shutdown valve shall be completely assembled and fitted with all
equipment such as actuator solenoid valve(s), etc. The stuffing box
shall be correctly packed and soap tested with 3.5 bar(g) air
pressure inside the valve body.
All required stroking times shall be checked.
If the valve is equipped with limit switches, they shall be checked
for functional operation with a proximity tester.

11.4 Seat Leakage Test

The seat leakage test shall be in accordance with API 598 / 6D Zero
Leakage. For each valve tested, the VENDOR shall state the following
data:
• Flow direction;
• Test medium;
• Test differential pressure;
• Seat leakage flow rate measured;
• Allowable seat leakage flow rate;
• Seat leakage class.

11.5 MATERIALS AND INSPECTION CERTIFICATION

Materials and inspection certificates shall be provided by Vendor.
 Rev No. Page 30 of
R01 31

12 WITNESSING BY ENGINEER/ COMPANY

The extent of the COMPANY's involvement in witnessing inspections and

tests at the VENDOR's works shall be minimized and shall be specified
on the requisition.
Upon request, a quality plan shall be submitted by the valve VENDOR.

13 PROTECTION AND PACKAGING

All necessary precautions shall be taken for adequate protection of

the valves, including accessories, during shipment and outdoor
storage at their destination. These precautions shall include the
following:
• Before leaving the factory, all openings in the valve body shall be
provided with temporary closures to prevent entry of dirt or other
materials.
• During transport and storage, the valve ends shall be protected
with suitable close fitting protectors (e.g. plastic caps) or covers
of at least 3 mm thick and securely fastened by an adequate number of
bolts.

Open threaded connections, e.g. air connections of actuators,

positioners and accessories, shall be fitted with thread protectors
to prevent the ingress of moisture.
• The stuffing boxes of valves with graphite-based packing shall be
protected against the ingress of moisture.

14 DOCUMENTATION

The VENDOR shall submit the following documents with the quotation:
• Details of the selected actuator and torque figures.
• Calculations of the predicted noise level, and, where applicable,
details of the secured instrument air vessel.
• Dimensional outline drawing of the shutdown valve, including
accessories, air lines and, where applicable, the secured air vessel.
• Details of where the full valve specifications will be held.
The results of the inspections and tests by the VENDOR shall be made
available to the COMPANY as part of a package of final certified
documents and drawings.
The VENDOR shall complete a spare parts list and interchangeability
record (E-SPIR) for all equipment supplied. See PTS 70.10.90.11.
Vendor shall also comply with the requirements of documentation
specified in Company procedure.
Rev No. Page 31 of
R01 31