VOL - 06 Page 72 of 296

ONGC, HAZIRA PLANT

DISCIPLINE:
INSTRUMENTATION

STANDARD SPECIFICATION FOR

REMOTE OPERATED VALVE
DOC NO : IOTDE/INST/CV/01

IOT DESIGN & ENGINEERING LTD.

REV NO : R0
ISSUE DATE : 14/09/2010
PAGE NO. 1

STANDARD SPECIFICATION FOR

REMOTE OPERATED VALVE

Prepared By

Checked By

Approved By

SD

GP

NM

This document is the property of M/s. IOTDE and must not be copied, used & reproduced without written permission from M/s IOTDE.

OF 10

VOL - 06 Page 73 of 296

ONGC, HAZIRA PLANT

DISCIPLINE:
INSTRUMENTATION

STANDARD SPECIFICATION FOR

REMOTE OPERATED VALVE
DOC NO : IOTDE/INST/CV/01

IOT DESIGN & ENGINEERING LTD.

REV NO : R0
ISSUE DATE : 14/09/2010
PAGE NO. 2

OF 10

CONTENTS
Clause No.

ITEM

Page No

1.0

Scope of this Document

2.0

Recommended Codes and Standards

3.0

Scope of Supply

4.0

Remote Operated Valve

5.0

Accessories

6.0

Painting

7.0

Installation Requirement

8.0

Calibration, Inspection and Testing

9.0

Documentation

10.0

Tagging and Nameplates

11.0

Packing and Shipment

12.0

Receipt and Storage

10

Data Sheet

----

Annexure-I

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VOL - 06 Page 74 of 296

ONGC, HAZIRA PLANT

DISCIPLINE:
INSTRUMENTATION

STANDARD SPECIFICATION FOR

REMOTE OPERATED VALVE
DOC NO : IOTDE/INST/CV/01

IOT DESIGN & ENGINEERING LTD.

REV NO : R0
ISSUE DATE : 14/09/2010
PAGE NO. 3

OF 10

1.0

SCOPE OF THIS DOCUMENT:

1.1

This specification describes the essential considerations in the selection, installation,

calibration and testing of Remote Operated Valve for Fire Fighting System.

1.2

The Vendor shall be responsible for the selection of Remote Operated Valve suitable for its
intended application, its design, engineering, packing, calibration, testing, shipment to site.

2.0

RECOMMENDED CODES & STANDARDS :

ANSI B 16.37
ANSI FCI 70.2
ISA S 75.01.01
ISA S 75.03
API 6FA
API 598
OSHAS
IEC 79
IEC 529
IEC 801
IS 2147
IS 2148
ASME B 16.5
API RP553
DIN 50049

: Hydrostatic Testing of Control Valves

: Leak Testing of Control Valves
: Flow equations for sizing control valves
: Face to Face Dimensions for Flanged Globe Style Control valves
: Fire Test for Valves
: Valve Inspection and Testing
: Occupational safety and health administration
: Electrical apparatus for Explosive Gas Atmosphere
: Classification of degree of protection provided by enclosure.
: Electromagnetic compatibility for industrial measurement & control
equipment.
: Degree of protection provided by enclosure for low voltage
switchgears and control gears
: Flameproof Enclosures for electrical apparatus.
: Pipe flanges and flanged fittings and finish.
: Refinery Control Valves.
: Document on material testing.

3.0

SCOPE OF SUPPLY:

3.1

The number of Remote Operated Valves to be supplied shall be as per the process
requirements indicated in the Data Sheet in this document.

3.2

The scope of supply shall also include commissioning spares and two years maintenance
spares as required and as suggested by the Manufacturer.

3.3

Supply of all items related to Remote Operated Valves indicated in this document are as
minimum, all additional items necessary for safe and efficient operation of the Valve which are
not listed specifically in the document but which are required as per vendors experience/
recommendation shall be in the scope of Contractor without any time & cost implication to
Client.

This document is the property of M/s. IOTDE and must not be copied, used & reproduced without written permission from M/s IOTDE.

VOL - 06 Page 75 of 296

ONGC, HAZIRA PLANT

DISCIPLINE:
INSTRUMENTATION

STANDARD SPECIFICATION FOR

REMOTE OPERATED VALVE
DOC NO : IOTDE/INST/CV/01

4.0

REMOTE OPERATED VALVE:

4.1

Valve Selection & Construction:

IOT DESIGN & ENGINEERING LTD.

REV NO : R0
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OF 10

4.1.1 The Contractor shall select Remote Operated Valve based upon plant capacity as per the
data sheet provided in the Annexure-I.
4.1.2

Valve selection shall consider all possible effect of erosion, cavitations and noise.

4.1.3

Maximum permissible noise level shall be 85 dBA at 1 m from valve in all direction.

4.1.4

Shut-off leakage of valves shall be in accordance with ANSIB16.104. Generally shutoff

shall be class IV or better. In General, valves shall be Drip-Free.

4.1.5

Body rating and flange rating and facing shall be in accordance with the piping class

4.1.6 Body casting shall be free from blowholes, porosity, cracks and other defects. Repairs of any
nature on such defects are not acceptable.
4.1.7 Bonnet material though not specifically mentioned shall be of the same material as valve
body. The same also applies to bonnet extensions where required.
4.1.8 Valve Packing boxes (where applicable) shall be flange bolted to the bonnet. Valve packing
shall be spring loaded and adjustable. Teflon V rings shall be used up to 2120C. Above this
temperature graphite shall be used with an external lubricator and isolation valve.
4.1.9 Valve bonnets shall be flange bolted to the body. Screwed bonnets shall not be provided. For
operating temperature of 2000C or greater, a radiating finned bonnet may be required. For
temperature below 00C an extension bonnet is required. If bellows seals are required they
shall be constructed from 316SS.
4.1.10 Minimum body size shall be DN25.
4.1.11 Pneumatic connections shall be NPTF as minimum. Larger Port sizes shall be used
wherever required for larger sizes of actuators.
4.1.12 Termination in wiring enclosures shall be via fixed terminals. Flying leads shall not be
permitted
4.1.13 Flow direction shall be stamped or cast on the body of all valves.
4.1.14 The offered make and model of the Remote Operated valve shall be certified / listed by
Underwriters Laboratory (UL) or BV or DNV for Fire Water Remote Operated service.
This document is the property of M/s. IOTDE and must not be copied, used & reproduced without written permission from M/s IOTDE.

VOL - 06 Page 76 of 296

ONGC, HAZIRA PLANT

DISCIPLINE:
INSTRUMENTATION

STANDARD SPECIFICATION FOR

REMOTE OPERATED VALVE
DOC NO : IOTDE/INST/CV/01

IOT DESIGN & ENGINEERING LTD.

REV NO : R0
ISSUE DATE : 14/09/2010
PAGE NO. 5

OF 10

4.1.15 Valve shall be sized as per the requirements of the platform for fire fighting.
4.2

Actuator:

4.2.1 Remote Operated Valve actuators shall be pneumatic, spring return type, diaphragm or
piston type. Spring shall be corrosion resistant, cadmium plated or equal. Piston type
actuator shall be used where diaphragm actuator cannot be used due to capacity limitation.
Electric actuator shall be used wherever specified.
4.2.2 Actuators shall be sized for operation under maximum shutoff pressure drop across the valve
minimum instrument air pressure or voltage to the actuator as specified in this specification.
4.2.3 Actuators shall be selected to achieve specified valve failure positions. All accessories,
including pilot valves, relays, volume bottles etc. for double acting actuator or air block
relays for fail in position valves, shall be supplied with the valve.
4.2.4 Detachable side mounted heavy-duty hand wheels shall be provided for Remote Operated
valves wherever specified.
4.2.5

Actuator action shall be field reversible.

4.2.6 Diaphragm actuators shall be multiple bolted, pressed steel with Nylon reinforced Neoprene
or Buna N Rubber Diaphragm.
4.3

Material:

4.3.1 The material requirements for Remote Operated Valves shall in general be according to the
Material Selection Chart provided in Annexure I of this document.
4.3.2 Remote Operated valve bodies shall generally be Cast 5% Al Bronze to BS 1400.A.B.2C.,
however more demanding services may require other materials as specified in the applicable
piping specification/ Material selection chart. Consideration shall be given in selection of all
other valve part materials for corrosion due to process fluid and ambient conditions.
4.3.3

Accessories such as mounting bolts shall be of SS 316.

4.3.4 Tubing shall be seamless 316 SS tube 3/8 OD minimum with 316 SS double ferrule
compression fittings.
5.0

ACCESSORIES

5.1

Solenoid Valve

This document is the property of M/s. IOTDE and must not be copied, used & reproduced without written permission from M/s IOTDE.

VOL - 06 Page 77 of 296

ONGC, HAZIRA PLANT

DISCIPLINE:
INSTRUMENTATION

STANDARD SPECIFICATION FOR

REMOTE OPERATED VALVE
DOC NO : IOTDE/INST/CV/01

IOT DESIGN & ENGINEERING LTD.

REV NO : R0
ISSUE DATE : 14/09/2010
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OF 10

5.1.1 This shall mounted on the actuator and fully tubed. Vent port on the solenoid valve shall be
suitably plugged with a SS whistle to prevent entry of dust/insects.
5.1.2 For details specification of solenoid valve refer attached Annexure-I
5.1.3

The Manufacturer of Solenoid valve shall be reputed one in India or abroad as specified in the
Annexure-II

5.2

Limit Switch

5.2.1

Limit Switch shall be mounted on the actuator yoke with provision for adjustment.

5.2.2

Each microswitch type limit switch whenever specified shall have its own separate housing
with ET threaded connection for cable gland. A common housing for more than one switch
is not acceptable. Housing shall be weather proof to IP65. Microswitch shall be SPDT type

5.2.3

Flameproof type limit switch wherever specified shall be as per IS2148, EN50014/EN50018 or
equivalent standard.

5.2.4

Inductive type limit switch shall be 2-wire type ( conforming to DIN 19234 / NAMUR
standard) 3-wire type as specified. Model No. shall be as given in approved vendors list.
Flexible leads from the switch shall be glanded and terminated in a junction box mounted
integrally with the actuator.

5.2.5

The junction box shall be weather proof to IP65 ( and flameproof to IS2148, EN50014/
EN50018 or equivalent standard if specified ). It shall have 2 Nos. ET threaded entries for
users cable glands. One of the entry shall be plugged with an aluminum plug.

5.3

Air Filter Regulator:

5.3.1 Air Filter Regulator shall be mounted on the actuator and fully tubed. The following
specifications will given:
a.

Type

: Dead end

b.

Body material

: Die Cast Aluminium

c.

Material of spindle & drain plug

: SS304

d.

Filter

: Sintered bronze, size 5 micron

e.

Connection size

: NPT(F)

This document is the property of M/s. IOTDE and must not be copied, used & reproduced without written permission from M/s IOTDE.

VOL - 06 Page 78 of 296

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DISCIPLINE:
INSTRUMENTATION

f.

STANDARD SPECIFICATION FOR

REMOTE OPERATED VALVE
DOC NO : IOTDE/INST/CV/01

Outlet pressure gauge

IOT DESIGN & ENGINEERING LTD.

REV NO : R0
ISSUE DATE : 14/09/2010
PAGE NO. 7

OF 10

: Required

5.3.2 Output pressure regulation and air handling capacity shall be selected by the vendor
depending on application.
6.0

PAINTING:

6.1

Valve body, bonnet, actuator, mounting plates for accessories etc. shall be degreased and
derusted before applying the epoxy coated paint.

6.2

Painting : Control valve Bonnet and actuator enclosure shall have epoxy coated painting of
minimum 150 micron DFT .

6.3

Bonnet and actuator shall be painted as follows based on Air Failure position:
Post Office Box Red
Green

: Air Fail to Close

: Air Fail to Open

6.4

Body shall be painted Grey for carbon steel materials and natural colour for Stainless Steel.

7.0

INSTALLATION REQUIREMENT:

7.1

The installation requirements of Remote Operated valve shall in general be according to

clause 3.6.4.6 Instrumentation Design Criteria.

7.2

Clearance shall be provided to allow in- line maintenance of valves. Adequate clearance
shall be provided above and below the valve and shall be installed on horizontal lines with
actuator as per manufacturers installation standards, and shall not impede access ways.

7.3

Remote Operated valve assembly shall be provided with double block, double bleed and
bypass piping and valves. The bypass valve shall be a globe valve no smaller than one pipe
size than the Remote Operated valve but with a CV no greater than that of the Remote
Operated valve.

7.4

Remote Operated valves shall be installed in the direction recommended by the

manufacturer and the valve shall not be subjected to stress due to pipeline movement or
misalignment.

8.0

CALIBRATION, INSPECTION AND TESTING:

8.1

Calibration, inspection and testing requirements shall in general be as per clause 3.6.4.7 of
Instrumentation Design Criteria.

This document is the property of M/s. IOTDE and must not be copied, used & reproduced without written permission from M/s IOTDE.

VOL - 06 Page 79 of 296

ONGC, HAZIRA PLANT

DISCIPLINE:
INSTRUMENTATION

STANDARD SPECIFICATION FOR

REMOTE OPERATED VALVE
DOC NO : IOTDE/INST/CV/01

IOT DESIGN & ENGINEERING LTD.

REV NO : R0
ISSUE DATE : 14/09/2010
PAGE NO. 8

OF 10

8.2

All valves shall be tested in accordance with API 589, hydro-tested t ASME B 16.34 clause
7.1 and leak tested to ASME / FCI 70.2.

8.3

Contractor shall remove in line instruments and Remote Operated valve and provide
necessary spool pieces/ Flanges prior to flushing/hydro testing.

8.4

All diaphragm and piston operated Remote Operated valve shall be stroked pneumatically
using a pressure regulator and pressure gauge against spring range shown on name plate
Mechanical sealing and travel shall be checked against name plate. Check shall be made in
shop prior to installation.

8.5

All Remote Operated valves shall be checked carefully against nameplate data and
specifications.

9.0

DOCUMENTATION:
Documentation shall includes Sizing Calculation and Data sheet, Technical Catalogue / CD,
Parts list for valve & accessories, Final Data sheet and sizing, Dimensional Drawing, QA
Procedure, Casting Certificate, Calibration and Stroke test Report, Leakage Test report,
Radiography Test Report, Instruction Manual with part drawings / CD, IS/flameproof
certification, Warranty Certificate against Serial number etc. shall be provided as per the
Vendor data requirement sheet.

10.0

TAGGING AND NAME PLATES:

SS Tag plates shall be supplied on the Bonnet side of the valve showing manufacturer name
along with the following as minimum.
Tag Number
Body and Port size
Stem Travel
Action on air failure
Spring Range
Air supply Pressure
Manufacturer Model Number for valve body, actuator and positioner.
P.O. Number

This document is the property of M/s. IOTDE and must not be copied, used & reproduced without written permission from M/s IOTDE.

VOL - 06 Page 80 of 296

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DISCIPLINE:
INSTRUMENTATION

STANDARD SPECIFICATION FOR

REMOTE OPERATED VALVE
DOC NO : IOTDE/INST/CV/01

IOT DESIGN & ENGINEERING LTD.

REV NO : R0
ISSUE DATE : 14/09/2010
PAGE NO. 9

OF 10

Serial Number
Leakage Class
Body rating and material grade
Signal range
Trim Characteristics
Body Test Pressure
Bench set Pressure
11.0

PACKING AND SHIPMENT:

11.1

Parts which may be damaged during shipment, shall be packed separately in the original
manufacturers boxes.

11.2

Each package shall be identified with purchase order number and content list in a
weatherproof envelope.

11.3

All opening shall be sealed. All flanged openings shall be protected with plastic discs to
avoid ingress of foreign material to the interior and to fully protect the flange faces.

11.4

All mechanical or machined surfaces subject to atmospheric corrosion prior to installation

on site shall be treated with an easily removable rust preventative. A desiccant shall be
provided inside all enclosures to prevent moisture damage due to high humidity .

11.5

Any plant component exceeding 40 Kg in weight shall be supplied with lifting lugs or eye
bolts. The lugs or eyebolts should be positioned such that the component can be readily
slung from a point over its centre of gravity.

11.6

The shipping notice shall be written on the box or crate with red letters, such as Handle
with Care / Keep Dry / Fragile, etc.

11.7

Each crate, bag or package shall be clearly identified with the purchase order number,
Purchaser and Destination address and identification symbol.

11.8

Vendor shall be solely responsible for the adequacy of the Preparation for shipment in his
Tender for review by Purchaser .

This document is the property of M/s. IOTDE and must not be copied, used & reproduced without written permission from M/s IOTDE.

VOL - 06 Page 81 of 296

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DISCIPLINE:
INSTRUMENTATION

STANDARD SPECIFICATION FOR

REMOTE OPERATED VALVE
DOC NO : IOTDE/INST/CV/01

IOT DESIGN & ENGINEERING LTD.

REV NO : R0
ISSUE DATE : 14/09/2010
PAGE NO. 10

OF 10

12.0

RECEIPT AND STORAGE:

12.1

The Contactor shall develop a comprehensive plan for receipt, storage and release of all
equipment released into his care, including items supplied by others or free-issued by the
Company.

12.2

This plan shall provide means to immediately establish the status and location of any item,
which has been issued to the Contractor.

12.3

The Contractor shall be fully responsible for equipment issued into his care, and shall provide
secure facilities to provide a storage environment, which shall protect the equipment to the
vendors requirements.

12.4

Any equipment damaged after issue to the Contractor shall be replaced, by the Contractor, at the
Companys discretion.

This document is the property of M/s. IOTDE and must not be copied, used & reproduced without written permission from M/s IOTDE.