The Supplier shall incorporate details of sub-supplier scope in their own documentation.The technical requirements contained in this specification are in addition to those defined by Purchaser in TR2000 “Piping and Valve Material Specification" and other referred standards and specifications.The minimum requirements herein are still applicable for the above excluded systems if the actuated valve is given an additional safety function to its original function in the process plant.Selection of actuator type is Purchaser responsibility and is described in TR3032 Field Instrumentation. Any information applicable for purchaser’s consideration to select mode of actuation, space requirements (maintenance, material handling etc.) and the effect on weight and equipment stability shall be highlighted by supplier.Actuator suppliers shall be accepted for use according to the list of approved suppliers located in TR2000 Piping and Valve Material Specification:www.tr2000.net —> Document Space —> Valve Technology and Requirements http://www.tr2000.net/TR2000/document space/list documents.jsp?document id=57&opn=The Purchase Order (PO) shall define the selected valve design and details, as well as the functional requirements by pre-selecting the control circuit function and thereby also define the selected actuator type (single/double acting, hydraulic/pneumatic/electric).The valve supplier shall have full responsibility for the design, construction and functionality of the valveactuator assembly including all accessories, local control circuits and accumulators. The valve supplier shall in close liaison with the actuator supplier calculate and select the most suitable actuator and control circuit capacity that will satisfy the requirements set forth in the PO’s.Actuator failure mode shall ensure the correct valve position required for the safe operating condition. Service life shall be minimum 20 years unless otherwise specified.The dimensioning of the actuator shall be valve supplier’s responsibility in close cooperation with the actuator supplier. A description of the required service application will be submitted in a Process Data Sheet (PDS). In addition, an Instrument Data Sheet (IDS) and a Valve Data Sheet (VDS) with referred attachments will be presented in the PO.Typical information provided by Purchaser will be: � Type and size of valve � Type of actuator � Line pressure � Maximum service media differential pressure � Operating temperature � Type of fluid in the line � Ambient temperature � Pneumatic/hydraulic/electric power supply � Opening/closing timesIn addition the valve supplier shall include (obtained from actuator supplier if relevant) experience data such as: � Valve stem size and packing design/compression � Valve wear and degradation � Relaxation of springs � Increase of valve torque and thrust when the valve is stationary in one position during a prolonged period of timeUnless otherwise specified, all equipment shall withstand humid and corrosive atmosphere. Special conditions like e.g. severe condensation, sea water, fire water spray, steam and AFFF may be specified in PO.General accessories such as nuts, bolts, indicator pins, etc., assembled in direct contact with stainless steel equipment, shall be in AISI 316 SS.For electric actuators, alternative use of aluminium material grades may be accepted if the aluminium grade(s) is documented as a corrosion resistant material grade in marine and saline atmosphere. If any aluminium grade is used, a proper specification shall be established as described in section 11.3.6.All welding shall be continuous and welding of stressed components shall be full penetration welds. When welding is applied onto components specified as 316 SS material, the material grade shall be AISI 316L.All equipment shall comply with the requirements of the specific hazardous area in which they will be installed.The equipment shall be certified for Zone 1, Gas Group IIA, and temperature class T3 as a minimum unless specified otherwise by Purchaser in PO.Preferred protection methods are Ex (e), Ex (i), and Ex (m) in accordance with IEC 60079. For field instruments like limit switches Ex (i) shall be used in maximum extent possible. For junction boxes and glands Ex (e) shall be used in maximum extent possible. For solenoid valves Ex (m) shall be used in maximum extent possible.The minimum degree of protection provided by enclosures shall be IP 56 in accordance with IEC 60529.Pneumatic/control valve solenoid coils shall be with completely encapsulated coil, screw terminals within terminal box and cable connection to be ISO metric, pitch 1.5 mm.The installation shall be done by skilled personnel who have participated in the applicable fitting manufacturer's training course or general tubing and compression fittings training course before they are allowed to work with tubing and compression fittings. A successful performance of the course shall be documented by a qualification certificate, which shall be accessible on request.The make and type of fittings will be specified in the PO. Instrument ball valves shall only be used for on/off operation.Fire resistant, braided flexible hose connection between the tube and the actuator final fitting may be considered when there is risk of high vibration and shall be approved by Company.Any loose items shall be put in a small plastic bag and fastened with ”strips” onto the equipment close to the applicable mounting position.5.7.2.2 Hydraulic & Nitrogen services For hydraulic applications, and N 2 services for hydraulics, compression tube fittings shall be used.Threaded end fittings (without adapters) shall be to ISO 1179-2 with BSPP threads to ISO 228-1, sealing surface to DIN 3852, form A, utilising a bonded seal packing in 316 SS/PTFE or 316 SS/NBR (Explosive decompression proof if used in Nitrogen service).All interface tube fittings shall be included in the equipment units and shall be plugged with suitable AISI 316 SS caps prior to shipment.All parts of the assembly shall be thoroughly cleaned by mechanical means before any washing or flushing is attempted. All tube ends, ports in solenoids etc. shall be de-burred on the outside and inside and blown through with air before assembly.5.7.2.3 Pneumatic service For pneumatic systems NPT threaded connections (ASME B1.20.1 or B1.20.2M) shall be used.All interface tube fittings shall be included in the equipment units and shall be plugged with suitable AISI 316 SS caps prior to shipment.On NPT-threaded compression fitting, the sealing compound for process services and instrument air services shall be recommended by purchaser. The use of PTFE tape can be used upon Company acceptance.The actuator control circuit represents the interface between different control/safety computer systems and the on/off valve. Schematic control circuits for hydraulic/pneumatic actuated valves are shown in App A and App B. Control panels for the different circuit types shall be standardised in size, layout and mounting arrangement.Valve control panels for on/off valves should be of “compact” type, avoiding internal tubing and fittings. All accessories required for control of the actuator movement, such as hydraulic inlet filter, solenoid valves, manual valves, pressure gauges etc. shall be mounted on a control panel.Hydraulic oil inlet and outlet ports shall be clearly marked "Oil Inlet" and "Oil Outlet", both on control panel and actuator. Isolation valves for supply and return lines shall be installed as close to the instrument as possible.Hydraulic filter units to be used shall have a differential pressure indication without an automatic bypass function.Pressure gauges shall indicate the internal pressure in the control unit.The electric motor shall be Class F insulated and rated for duty at an ambient temperature of + 40 deg C or specified maximum ambient, whichever is the highest, for a minimum of 15 minutes or twice the valve stroking time, whichever is the longest, and with an average load of 33 % of the maximum valve torque.Electric motors shall be in accordance with the requirements in TR3122 Three phase cage induction motors, sections 2.1, 2.2, 3.3, and 3.5.6.2.2 Testing Testing of electric motors shall be performed in accordance with TR3122 section 5.2.The valve/actuator assembly shall be designed to avoid high component stresses, instability between valve and actuator, high deflections or other operational problems. The actuator shall be supported by the valve. Supporting shall not be by adjoining pipe or other external structures unless this is agreed between purchaser and supplier and included in the PO.Junction- and limit-switch boxes, limit switches, position indicators and other ancillaries connected to actuators, adapters and accumulators shall use rugged and solid methods for attachment.When the valve/actuator will be installed oriented horizontally the stem deflection shall be considered in the design and shall not be larger than 2% of the stem diameter, measured at the stem-coupling. Any spot check verification is to be agreed between purchaser and supplier and included in the PO.All valve assemblies including the control circuits may be specified to withstand explosion loads and earthquake loads. Purchasers shall in the PO identify explosion load requirement by providing a Design Accidental Load Specification that will identify blast loads for the various areas of a plant.Flexible hoses may be used subject to Company approval. Alternatively, hard tube shall be installed to allow safe operation due to relative movements of the actuator/accumulator during an explosion.The actuator shall be provided with a local indicator showing the valve position at all times. Where fire protection shield is applicable, valve position shall be visible outside such protection. When a mechanical device/indicator is fitted, the Open and Closed position indication shall be permanent/engraved.All components that will require adjustments (e.g. piston end-stops, limit switches) shall use threaded components for adjustment and locking.Yoke and gear housings shall be completely weather proof. They shall be pre-lubricated for expected life and oil filled housings shall be filled to submerge all moving parts.Whenever rotary or linear shafts enter into a closed compartment (e.g. piston rods, limit switch shafts) weather seals (lip-seal, O-ring) shall be fitted as flush as possible with the external surface. This is to avoid entry of water and dirt.The equipment shall be designed so that water does not accumulate in pockets/depressions on the exterior, and is not trapped inside low-point volumes internally, causing corrosion. Drain facilities shall be included if this is not possible to avoid.Spring housings and unpressurized parts of the piston cylinders shall be of closed design and not exposed to atmosphere internally. This can be achieved by sealing the housing or e.g. connecting to instrument air.Thrust/torque verification, limit switch settings, dimensions, function, and identity shall be verified against relevant documents and drawings.All equipment and individual parts shall be delivered fully tested, in accordance with these technical requirements, codes and data sheets, to guarantee the performance of the equipment.The technical condition/ranges of all test equipment used for the different tests shall be capable of verifying all requirements specified within this document.All test equipment shall hold a valid calibration certificate. Hydraulic test rigs and pneumatic supplies shall have sufficient capacity to meet the required performance of the valve assemblies and control circuits as defined by purchaser.The medium used in the main (piping) valve shall be potable water with chloride content less than 30 ppm with added corrosion inhibitor to protect the valve internals. The valve shall be cleaned and dried after testing. Water shall not be used for valves that will be used in cryogenic service. Test medium for such valves shall be agreed with purchaser.Hydraulic test equipment shall be cleaned to ISO 4406, class -/14/10 prior to any test. An electronic particle counter, or equivalent, with printout shall be used for documentation of the cleanliness level.No Teflon tape or equal sealing material shall be used on test equipment. The various tests can be combined where found advantageous and agreed with the Purchaser.The test shall include adjustment/control of stroke/alignment of valve, actuator and limit switches. Correct operation of limit switches shall be verified.All units shall be individually subjected to a function test in accordance with specified requirements. These may be manufacturers standard tests (subject to Purchaser's approval), but tests shall satisfy the requirements defined herein.� Valve test to verify leak, pressure, thrust/torque, etc. � Actuator test to verify performance, static pressure test, internal/external leak test, cleanliness, etc. � Control Circuit test to verify capacity, internal/external leak test, pressure test, function test, cleanliness etc. � Accumulator tests (third part verification, if applicable), leak and pressure tests, cleanliness, etc.9.2.2 Documents present at test stand The following documents and drawings shall be present at function/factory acceptance tests:� Purchaser’s Process Data Sheet � Valve, Actuator and Control Circuit Dimensional Drawing � Operating Diagram/Hook-Up Guidance for Control Circuits � Test ProceduresThe following documents shall be made available upon request: � Purchaser’s Valve Data Sheet � Actuator Sizing Calculations � Accumulator Sizing/Capacity Calculations� Valve Test Records/Certificates, (Torque/Thrust Figures) � Actuator Test Records/Certificates, (Torque/Thrust Figures) � Control Circuit Test Records/Certificates, (Leak/Static Pressure Test) � Wiring Diagram, Limit Switches, Solenoids � Test Rig Certificates, Cleanliness, Instrument Calibration Certificates � Agreed Deviations � Purchaser’s Instrument Data Sheet � Documentation of conformance with IEC61511 and IEC61508 for the complete valve assembly (e.g.,All applicable units (actuators, control systems, accumulators) shall be leak tested for a period of minimum 15 minutes after pressure stabilisation. A recorder shall be used. Test pressure shall be 110 % of maximum supply pressure.Acceptance criteria: The system shall be considered approved when test-pressure decreases less than 0.5 bar/15 min and there are no visible leaks or sweating.All applicable units (actuators, control systems, accumulators) shall be leak tested with a soapy solution, checking all fittings and connections. Test pressure shall be 110 % of maximum supply pressure.Test-medium: Clean air or nitrogen. Acceptance criteria: The units shall be considered acceptable when no leaks are found (bubble-tight).1. In the actuator/valve open position, the ZSH signal shall be positive. No signal shall be indicated from ZSL. In the actuator/valve closed position, the ZSL signal shall be positive. No signal shall be indicated from ZSH. Record results.2. The assembly shall be stroked a minimum of 3 strokes for valves 14” and above and a minimum of 5 strokes for 12” and below to verify repeatability. Travelling time to be monitored and shall be on a steady level for the specified no of cycles to be accepted. Record results.Check manufacturers individual test records for the control circuit, actuator and bare stem valve. All tests as defined for the function tests shall be performed, utilising the dedicated control circuit to operate the valve-assembly. The test shall verify the performance of the assembly, and confirm the performance recorded during the FAT tests of the individual parts. The test shall also verify that the selected actuator will operate the valve at minimum actuator supply pressure, with maximum differential pressure across the valve.1. Test 1 shall be performed with speed control valves in the fully open position. Apply maximum differential pressure across the valve (as agreed with purchaser to be dimensioning for the actuator sizing). The test shall include verification of the required valve torque/thrust with the maximum differential pressure across the valve. This may be done by recording the necessary pressure to operate the actuator and calculation of torque/trust (actuator internal friction to be considered). The obtained value shall be compared with the torque/thrust result from the bare stem valve test. No increase in torque/thrust shall be accepted. (If no bare stem test record is available, the test result shall be compared with the theoretical valve requirements used for actuator sizing). Record results and confirm the safety factor requirements as specified in 3.3.3.2. Test 2 shall be performed with speed control valves in the fully open position. Repeat test 1 at minimum, normal and maximum supply pressure to control circuit/actuator. Record travelling times.3. Close speed control valves fully and operate the valve open/close at normal actuator supply pressure. The valve shall complete the open/close stroke fully. Record travelling times.4. Apply normal supply pressure to the control circuit and set speed control to suit travelling time requirements as defined in the Purchaser's IDS/PDS.5. Verify fail safe operation of the valve/control circuit by simulating electric signal loss with the maximum differential pressure applied across the valve. This step is meant to verify the capability of the actuator to operate the valve to fail-safe position under the most onerous condition. For fail-safe close valves the obturator can be placed in the “start-to-close” (i.e. the point of travel where the obturator first starts to seal off the bore) position prior to the pressurization and subsequent signal loss.All surfaces in contact with hydraulic oil shall be machined. Raw as-cast or forged surfaces are not permitted (cylinder end covers, pistons etc.).Before shipment (after painting) all hydraulic equipment described in this document, including valve actuators, shall be flushed to a cleanliness level according to ISO 4406 class -/14/10 or better. Flushing shall be performed in accordance with a written flushing-procedure, conforming to requirements specified in NS 5910. Supplier shall purchase all hydraulic main components with a documented cleanliness level according to this standard. These components shall be by-passed during assembly system flushing, so as not to contaminate already cleaned components.Storage, handling and assembly of the actuator parts shall be such to prevent any ingress of foreign material and pollution. The specified hydraulic oil shall be the only lubricant used during assembly of the hydraulic cylinder, piston, rod and seals.An electronic particle counter, or equivalent, with printout shall be used for documentation of the cleanliness level.Maximum allowed water content shall be less than 50 % of the relative saturation at + 20 °C.The interface fittings between flushing equipment and equipment to be flushed shall conform to the specified project instrument tube-fittings for the control system. After completed flushing these fittings shall not be removed, but plugged by nominated instrument fittings, to maintain the cleanliness requirements. Labels shall be attached to these sealing fittings with the following text: "System flushed to ISO 4406, class -/14/10. Only to be removed by authorised personnel".All carbon steel components and surfaces exposed to the atmosphere shall be coated. All surface protection shall be according to TR0042.10.2 Colours The color codes for valves and actuators shall be according to TR0042.Documentation shall be supplied in accordance with TR2381, TR0052 (applicable for project specific documentation) and additional requirements specified herein.Documentation comprises Life Cycle Information (LCI) specified in TR2381 and Project Documentation specified herein. Project Documentation is documentation needed in the project phase in order to ensure correct quality of delivered valve assemblies. Project Documentation shall not be stored in SAP, and may be disposed by Purchaser when the valve assemblies have been taken into use.Company’s acceptance of Supplier’s documentation does not constitute approval in the sense that Company assumes responsibility for the correctness of the contents.Documentation from actuator supplier shall not be modified or added new or different drawing frames as this will reduce readability of the documentation. If required, valve supplier logo, contractor logo and document numbering other than the numbering given by the actuator supplier shall be added on the original document format located on available free space or as an additional front page. Page numbering shall not be revised.