FS SSIV Actuator

Design Division Spec # 3509

Engineering Services Rev # 0

11 - High, Mumbai Discipline Instt.

ISO 9001: 2000

Functional Specifications

SUBSEA

INTERVENTION

VALVE ACTUATOR Page # 1 of 11

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:

DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006

FUNCTIONAL SPECIFICATION

FOR

SUBSEA INTERVENTION VALVE

ACTUATORS

PREPARED /

REVISED BY

REVIEWED

BY APPROVED BY

TOTAL

No. OF

PAGES

DATE REV.

No.

VS SSK GRP 11 16.06.08 0




ISO 9001: 2000


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INTERVENTION



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CONTENTS

Clause No. ITEM Page No.

1.0 Scope of This Document 3

2.0 Scope of Supply 3

Sub sea Intervention Valve Actuator 4

3.1 Design & Construction 4

3.2 Material 7

3.0

3.3 Manufacture’s qualification 7

Miscellaneous 7

4.1 Inspection & Testing 7

4.2 Non destructive testing requirements 8

4.3 Valve / Actuator assembly test 8

4.4 Extent of inspection & testing 8

4.5 Tests certificate report 9

4.6 Painting & Marking 9

4.7 Spares & accessories 10

4.8 Documentation 10

4.0

4.9 Warranty 11




ISO 9001: 2000


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INTERVENTION



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1.0 SCOPE OF THIS DOCUMENT:

This specification covers the minimum requirements for design, manufacture,

inspection and testing of subsea intervention valve actuators suitable for

installation on ball valves in submarine pipeline systems handling hydrocarbons in

liquid or gaseous phase and injection Water.

This specification shall be read in conjunction with Functional specification for sub

sea Ball valve, Hydraulic Power Unit (HPU), Umbilical.

HPU – cum- Control panel and umbilical sizing shall be the responsibility of the

actuator vendor. Subsea intervention valve system consisting of subsea valve,

subsea actuator, HPU-cum-Control panel etc. shall be supplied with single point

responsibility functional specification describes the essential design considerations

for the selection of subsea intervention valve actuator for the intended service.

2.0 SCOPE OF SUPPLY:

2.1 The quantity to be supplied and installed shall be as per the requirements indicated

in the Basic Bid Work, Design Criteria and the P & IDs.

2.2 The vendor shall be responsible for the selection of the subsea intervention valve

actuators suitable for its intended application, its procurement, tagging, packing,

testing & calibration, preparation for shipment, along with accessories, spares, and

assistance where required for its installation & commissioning at site. This FS shall

be read in conjunction with:-

• Instrumentation Design Criteria

• Basic Bid Work

• Project P & IDs

• Process Design Criteria

• Electrical Design Criteria

• Piping Design Criteria

• Mechanical Design Criteria

• Environmental condition of the project

2.3 Reference has been made in this specification to the latest edition, enforce at the

time of issue of enquiry of the following applicable Codes, Standards and

Specifications.

ASME B 31.3 Process Piping




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ASME B 16.5 Steel Pipe Flanges and Flanged Fittings

ASME B 16.47 Large Diameter Steel Flanges

MSS-SP-44 Steel Pipeline Flanges

SSPC-VIS-1 Steel Structures Painting Council Visual Standard

DNV-1981 Det Norske Veritas – Rules for submarine system

3.0 SUBSEA INTERVENTION VALVE ACTUATORS

3.1 DESIGN AND CONSTRUCTION

3.1.1 Actuators for operating subsea ball valves shall be designed for permanent subsea

Installation in water depth and service conditions indicated in Actuator Data Sheet

/process data sheet.

3.1.2 Actuator design shall be of scotch-yoke /rotary vane / helical spline type

mechanism. The actuator design shall maintain the selected valve position fully

open or fully closed and shall ensure the FAIL SAFE (denergize to close in case of

subsea intervention valves) condition of the sub-sea valve as per the process

requirement. Requirement of Fail safe or fail locked shall be described in

P&ID/Process design criteria.

3.1.3 Actuators shall be designed for operation by hydraulic fluid at pressures ranging

from 70 kg/Cm2 (g) normal to 105 Kg/Cm2 (g) maximum from Hydraulic Power

Unit (HPU) via Control Umbilical. In addition, actuators shall also be designed for

operation by hand held Nitrogen Cylinders by divers. HPU shall be stationed on

the Platform and shall be stationary unless otherwise specified.

3.1.4 Actuators shall be designed for an operational life of 25 years, unless specified

otherwise; Actuators shall be designed to be maintenance free during the

operational life.

3.1.5 Manufacturer shall size the actuator to match the valve torque requirements. For

the purpose of sizing the actuators, the torque output with 70 kg/cm2 (g)

hydraulic pressure shall be at least twice that required to operate the ball valve

under the maximum differential pressure corresponding to the valve ANSI rating.

However, the maximum actuator torque output with 105 Kg/Cm2 (g) hydraulic

pressure shall not exceed the maximum allowable torque on the valve stem.




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3.1.6 Actuator body shall be designed to comply with ASME B 31.3 and all body joints

shall be accordance with ASME Boilers and Pressure Vessels Code, Section VIII,

Division-1.

3.1.7 All pressure and load carrying components in the actuator shall be designed to

withstand the maximum output torque from the actuator without affecting the valve

performance. A factor of safety of at least 2.5 on the ultimate tensile strength of

materials shall be used for load carrying components that are not covered by

ASME B 31.3.

3.1.8 Actuator shall be capable of opening or closing the valves within the time

calculated based on 0.75 and 3 seconds per inch of valve nominal bore, unless

otherwise specified in the process description of work in the bid. Provision shall be

made for slower actuation during maintenance and field testing activities.

3.1.9 Actuator design and configuration shall be such as to ensure smooth valve

operation without imparting any residual lateral loads on the valve stem so as to

ensure balanced torque on the valve stem.

3.1.10 Actuators shall be supplied mounted on the valve, unless specified otherwise. In

case actuators are not to be mounted on valves, Manufacturer shall supply the

actuator loose. These actuators shall normally be stored on a surface facility and

will be taken subsea only when required for valve operation. Such actuator shall

comply with all requirements of proven design, umbilical connection, torque

requirements, etc. as indicated for the actuators to be mounted on the valves.

3.1.11 Actuators shall be supplied with a supply type adopter suitable for mounting on

valve stem. Provision shall be made to mount the actuator on the valve in such a

way that it can easily be installed or replaced by divers. Actuators, whether

permanently mounted on valve or supplied loose, shall be supplied with diver

quick release system to facilitate easy removal and installation by divers, when and

if necessary.

3.1.12 Open-Close Status indication of sub sea Valve shall be made available on HPU

panel through limit switches / proximity switches installed on the valve actuators.

Connection shall be provided for the hydraulic fluid supply to the actuator and

exhaust hydraulic fluid return to the surface. Hydraulic fluid inlet and outlet

connections shall be ¾” NPT and all external connections shall be provided on the

underside of the actuators to reduce any possibility of damage. It shall be possible

for divers to safely make and break the connection between the actuator and HPU

umbilical/ Nitrogen cylinder umbilical while the system is pressurized.

3.1.13 For connection with the surface HPU (through umbilical) or with diver held

nitrogen cylinder , the actuator body ports shall be connected by tubing to a

junction plate consisting of :




ISO 9001: 2000


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• Four No. SS 316 ¾” NB quick connect / disconnect coupling made half with

self sealing check valves (One primary and one spare set).

• Four no. SS 316 ¾” NB isolation valves, one for each coupling.

• Four Nos. SS 316 3/8” NPTF drain or flush valves.

• One no. SS 316 3/8” NPTF by-pass valve.

3.1.14 In case of operation of actuators by divers, suitable arrangement shall be provided

to exhaust the hydraulic fluid into the sea.

3.1.15 The hydraulic fluid used for operating the actuators shall be water based , bio-

degradable type with requisite addition of biocide and shall have a cleanliness

level of NAS1638, Class-6. The actuator shall be supplied filled with hydraulic

fluid.

3.1.16 Valve position indicator shall be provided as an integral part of the actuator. The

indicator shall be in line with the pipeline, when the valve is open and transverse

when the valve is closed. The system for indication to the diver shall not have

moving parts exposed to sea water and shall be covered by a transparent plate to

enable the diver to identify the valve position visually even inn poor visibility

conditions. A removable cover shall be bolted to the actuator to prevent marine

fouling from obscuring the view of the indicator.

3.1.17 When specified in P&ID/Data Sheet/Specification, provision shall be made for

valve open/close status (through actuator and umbilical) at the HPU control panel.

Necessary details shall be furnished for Company’s approval.

3.1.18 Mechanical stops shall be provided to limit the actuator travel.

3.1.19 Where necessary, seals shall be provided on the actuator body to prevent leakage

from the actuator to the environment and to prevent seawater leakage in the

actuator body under external hydrostatic pressure. The external hydrostatic

pressure considered in design shall correspond to a pressure of 1.5 times the

hydrostatic head at the installation location.

3.1.20 Threading shall be NPT as per ASME B 2.1 and flange connections shall be as per

ASME B 16.5. The tubing, fitting, valves and disconnect couplings shall be SS 316

stainless steel with fittings swage lock or equivalent. All tubing shall be properly

supported and shielded from damage by a suitable protective cover.




ISO 9001: 2000


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INTERVENTION



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3.2 MATERIALS

Actuators shall be supplied with SS 316 L stainless steel trim. Materials of all parts

and seals shall be compatible with the operating hydraulic fluid. All materials shall

be suitable for permanent installation in subsea environment and all exposed parts

shall be resistant to seawater corrosion.

3.3 MANUFACTURER’S QUALIFICATION

Manufacturer who intends bidding for subsea valve actuators must submit along

with the Bid, the relevant information and details as mentioned in 5.8.12 of this

specification to establish that the type of subsea actuator offered are field proven

for permanent subsea installation in similar service for the last five years and are

functioning satisfactorily. Subsea actuators of design not installed in the last five

years in similar installation (size, rating and water depth corresponding to

applicable valve) and service conditions are not acceptable.

4.0 MISCELLANEOUS

4.1 INSPECTION AND TESTING

The actuator Manufacturer shall perform all inspection and tests as per the

requirements of this specification and the relevant codes at his works. Prior to

shipment to valve Manufacturer’s Works. Such inspection and tests shall be but not

limited to the following:

4.1.1 Complete actuator housing with internals including the open/close hydraulic

circuits of all actuators shall be subjected to a hydrostatic test, the hydrostatic test

pressure shall be as per process requirement of the bid. The test pressure shall be

applied for a minimum period of 2 hours. Pressure shall be monitored by chart

recorder. No leakage shall be permitted during the test.

4.1.2 Actuator operation test shall be carried out by mounting the actuator on a torque

rig, applying the hydraulic pressure of 70Kg/Cm2 (g) and carrying out torque tests

every 150 for both open and close strokes. The actuator shall be successfully

stroked 5 times in each direction by suitably applying the hydraulic pressure.

Torque figures shall be recorded for open and close strokes. Actuator position

indicator shall be checked for correct operations during the test. The torque

generated shall comply the requirements stated in section 5.0 of this specification.

This test shall be carried out on all actuators.

It shall be demonstrated that by applying 105 Kg/Cm2 (g) hydraulic fluid pressure,

the torque developed does not exceed the maximum permissible stem torque of the

valve, on which the actuator is to be mounted.

4.1.3 The actuator including the mounting spool shall be hydrostatically tested externally

with a pressure equivalent to 1.5 times design water depth indicated. One actuator

from each size shall be tested for 24 hours. The actuator shall be fully stroked i.e.




ISO 9001: 2000


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INTERVENTION



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open-close-open at least 10 times during this period. All other actuators of the

same size shall be hydro tested for a minimum period of 1 hour. There shall be no

evidence of internal leakage during the test.

4.1.4 Operation of all actuators with nitrogen cylinders shall be checked, to comply the

requirements stated in section 6.

4.2 NON DESTRUCTIVE TESTING REQUIREMENTS

4.2.1 Non-destructive examination of individual actuator material and components,

consisting of but not limited to castings, forgings, plate and assembly welds shall

be carried out by the Manufacturer.

4.2.2 All castings of pressure containing parts shall be radio graphically examined as per

ASTM E-94 and E-186/E-280 or EE-446 as applicable, at quality level 2-

2Tcategory A, B or C defects shall not exceed the severity level for Class 2.

Category D, E.F or G defects shall not be accepted.

4.2.3 All forgings shall be ultrasonically examined to ASTM A-609 Quality 1 will be the

minimum level of acceptance.

4.2.4 All machined surfaces shall be liquids dye penetrant examined as per ASTM E-

165. Surface discontinuities shall not be acceptable.

4.2.5 Sealing areas within the actuator body shall be completely inspected by Magnetic

particle methods in accordance with ASTM E-709. Surface discontinuities shall

not be acceptable.

4.3 VALVE/ACTUATOR ASSEMBLY TEST

4.3.1 After testing of individual actuators has been completed, the actuators shall be

mounted on valves. Integrated valve and actuator tests shall be carried out at the

Valve Manufacturer’s Works, in compliance with the requirements stated in

relevant Company specifications for subsea ball valves.

4.3.2 Company reserves the right to perform stage wise inspection and witness tests as

indicated at Para 6.1 above at Manufacturer’s works prior to shipment.

Manufacturer shall give reasonable access and facilities to the Company’s

Inspector.

4.3.3 Company reserves the right to require additional testing at any time to confirm or

further investigate a suspected fault. The cost incurred shall be to contractors’s

account.

4.3.4 Inspection and tests performed/witnessed by the Company’s Inspector shall in no

way relieve the Manufacturer to perform the required inspection and tests.

4.4 EXTENT OF INSPECTION AND TESTING

All actuators shall be tested in accordance with the requirements of Section 6.0 of

this specification. Actuator operation tests as well as the hydrostatic tests shall be

witnessed by the Company Inspector.




ISO 9001: 2000


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INTERVENTION



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4.5 TEST CERTIFICATES/REPORTS

Manufacturer shall submit the following certificates/report:

4.5.1 Mill test certificates relevant to the chemical and mechanical properties of the

materials used for the actuator pressure containing parts as per the relevant

standard and specifications.

4.5.2 NDT reports for radiography, ultrasonic, magnetic particle and liquid penetrant

inspection.

4.5.3 Test report on operation of actuators including torque and operating time.

4.5.4 Test report on internal and external hydrostatic test of actuators.

4.5.5 Test report on actuator/valve assembly tests.

4.5.6 All other actuator test reports and certificates as required by these specifications.

4.5.7 The certificates shall be valid only when signed by Company’s Inspector. Only

those actuators which have been certified by Company’s Inspector shall be

dispatched from Manufacturer’s Works.

4.6 PAINTING AND MARKING

4.6.1 Actuator surface shall be thoroughly cleaned, freed from rust and grease and

applied with sufficient coats of corrosion resistant paint suitable for marine

environment and suitable for long term sub-sea service. Surface preparation shall

be carried out by short blasting to SP-6 in accordance with “ Steel Structures

Painting Council - Visual Standard SSPC – VIS-I “. Manufacturer shall indicate

the type of corrosion resistant paint used in the drawings submitted for Company

approval.

4.6.2 In addition to the corrosion resistant paint, entire actuator surface shall be provided

with auditable antifouling coating to overcome rapid growth of fouling

organisms/marine growth during the operational life of the actuator. Points

requiring access during diver operations shall be coated with phosphorescent

materials which can absorb the light and retain the glow. So that these points can

be easily identified by the diver before operation.

4.6.3 All bolting and nuts exposed to the sea water environment shall be coated with

XYLAN /PTFE or shall be plated with Zinc as per ASTM B 633 Type-II SC3. In

addition, all threads exposed to sea water shall be provided with plastic caps, to

prevent the ingress of seawater.

4.6.4 All actuators shall be marked as per Manufacturer’s standard and shall have a

permanently attached stainless steel name plate with the following details :

• Tag Nos.

• Manufacturer’s Name.

• Actuator Type, Model No. Serial No.




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• Actuator Torque Rating.

• Design Water Depth in m

• Suitable for mounting on valves with Stem size, Valve size, ANSI Rating of

Valve.

4.7 SPARES AND ACCESSORIES

4.7.1 Manufacturer recommend spares for the actuator shall be supplied by the

contractor considering requirements for commissioning and two years of normal

operation.

4.7.2 In addition, Manufacturer shall recommend and submit the list of accessories and

special tools required for operation and maintenance of the actuators.

4.8 DOCUMENTATION

Following documents shall also be submitted to the company for review along with

the PR:

4.8.1 General arrangement and sectional drawings showing clearly the design features

and materials.

4.8.2 Technical catalogues giving technical specification and other information for each

type of actuators and its accessories.

4.8.3 Detailed sectional drawings showing all parts with reference number and materials

specification.

4.8.4 Assembly drawing with overall dimensional details.

4.8.5 Actuator sizing calculations including the relationship between required torque

valve and actuator output torque.

4.8.6 Welding procedure, testing procedures including the details of actuator torque

testing and quality control procedures.

4.8.7 Procedure for external hydrostatic test.

4.8.8 Details of hydraulic fluid proposed for filling the actuator.

4.8.9 Details of quick disconnect coupling system provided on the actuator.

Details of corrosion resistant paint, antifouling coating and radium /

phosphorescent coating proposed to be applied on the valve surface.

4.8.10 Details regarding the nitrogen quality along with pressure required for operating

the actuator from full open to full close under maximum differential pressure

corresponding to ANSI valve rating.

4.8.11 Reference list of similar supply of actuators with all relevant details including

Project, Year, Client, Location, Size, Relation, Service, Water depth, etc. wherein

the actuators have been installed in subsea installation in the last five years.

4.8.12 Contractor shall submit to the company following test certificates / reports as per

clause number 4.5 of the specification.




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4.8.13 Manual for installation, erection instruction, maintenance and operation

instructions including a list of recommended spares for actuators.

4.9 WARRANTY

Vendor shall have final and total responsibility for the design and mechanical

performance of all equipment supplied under this specification. Vendor shall

warrant the equipment furnished by him and the performance of the said

equipment in accordance with this specification. Also refer to Warranty clause as

given in bidding documents (Volume I).

FS SSIV Actuator

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