1.0
TECHNICAL
SPAN TS 1701:2015
SPECIFICATION
INSTRUMENTATION AND CONTROL
Part 1: Actuator
Sewerage Regulatory Department
No part of this publication may be reproduced, distributed, transmitted, stored in a
retrieval system, or reduced to any electronic medium without the written authority of
National Water Services Commission.
National Water Services Commission and Registered Certifying Agencies employees
are permitted to copy and use the information in this publication, for internal
purposes only.
Changes may be made periodically to the information herein.
First Edition
December 2015
Published by
Suruhanjaya Perkhidmatan Air Negara
(National Water Services Commission)
Prima Avenue 7, Block 3510
Jalan Teknokrat 6
63000 Cyberjaya Selangor
Malaysia
SPAN TS 1701:2015
FOREWORD
National Water Services Commission (SPAN) was established in 2008 to regulate
the water services industry in Malaysia. SPAN envisions a sustainable, reliable and
affordable water services for all by regulating water services industry through fair,
effective and transparent implementation of the Water Services Act (Act 655). Since
its inception in 2008, SPAN has been striving to institute improvements in term of
standards and performance in the country’s water and sewerage services sector.
SPAN aims to enhance efforts towards improving standards, quality and operational
efficiency of water and sewerage services industry to ensure sustainability. One of
the approaches is to achieve higher standards and quality by developing technical
specifications for products and systems. Hence, Technical Working Groups had
been formed by Sewerage Regulatory Department to formulate technical and
performance specifications for adoption in the sewerage industry.
This Technical Specification is a result of joint effort by members from various
relevant stakeholders of the industry. It forms part of the Instrumentation and Control
specifications which will be developed in stages; hence entitled Technical
Specification for Instrumentation and Control - Part 1: Actuator.
The specification contains key criteria on expected performance and operational
requirements specifically for electric type actuator. Electric actuator is found to be
more common in sewerage facilities compares with the pneumatic and mechanical
types in view of its suitability in application. With the fast evolving technology couples
with proliferation of actuator products in the market, the implementation of this
specification is vital to better regulate and gain control over the quality and output
performance of electric actuators.
The continual development of technical and performance specifications is crucial in
moving the industry towards higher standards which will uplift the image of local
sewerage industry. With the publication of this Technical Specification, it is hoped
that it will contribute towards a better planned and well organized development of
new sewerage systems to fulfil whole life infrastructure obligations.
Dato’ Mohd Ridhuan bin Ismail
Chief Executive Officer
National Water Services Commission (SPAN)
SPAN TS 1701:2015
COMMITTEE REPRESENTATION
Members of Technical Working Group on Technical Specification for Instrumentation
and Control, Part 1: Actuator:
Ms. Punita Nook Naidu
Mr. Iwan Nazri bin Mohd. Nordin
Ms. Sim Lee Gaik
Mr. Mohd Roslee bin Mahyudin
Mr. Mohd Fakhrur Rodyi Bin Bahrom
Mr. Ruzaini Ahmad Jani
Mr. Tan Choon Seong
Mr. Mohd. Helmi bin Mohd Shamsudin
Mr. Tang Mun Hong
Mr. Winston Yoong
Mr. Loo Chin Fook
Mr. Albert Thing
Mr. Dennis Tay
Mr. Tan Eng Chan
Mr. Yau Wai Yuen
Ms. Wong Kit Yuan
SPAN
SPAN
SPAN
SPAN
SPAN
IWK
IWK
IWK
Rotork (Malaysia) S/B
Rotork (Malaysia) S/B
Encord S/B
Actuation & Controls Engineering S/B
Dostek Engineering S/B
Dostek Engineering S/B
AHF Industries S/B
AHF Industries S/B
SPAN TS 1701:2015
CONTENTS
Page
1.0
Scope ...................................................................................................... 1
2.0
Common specification for electric actuator .............................................. 1
2.1
General .................................................................................................... 1
2.2
Actuator sizing ......................................................................................... 1
2.3
Environmental.......................................................................................... 2
2.4
Enclosure ................................................................................................ 2
2.5
Motor ....................................................................................................... 2
2.6
Motor protection....................................................................................... 3
2.7
Gearing .................................................................................................... 3
2.8
Hand operation ........................................................................................ 3
2.9
Drive interface ......................................................................................... 4
2.10
Local controls .......................................................................................... 4
2.11
Integral starter and transformer ............................................................... 4
2.12
Wiring and termination ............................................................................. 5
2.13
Commissioning kit ................................................................................... 6
2.14
Performance and test certificate .............................................................. 6
2.15
Safety protection...................................................................................... 6
3.0
Mechanical type electric actuator ............................................................ 7
3.1
Remote valve position/actuator status indication ..................................... 7
3.2
Local position indication .......................................................................... 8
3.3
Remote control facilities .......................................................................... 8
3.4
Monitoring facilities .................................................................................. 9
3.5
Torque and limits ..................................................................................... 9
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SPAN TS 1701:2015
Digital type electric actuator .................................................................... 9
4.0
4.1
Remote valve position and status indication ............................................ 9
4.2
Local position indication ........................................................................ 10
4.3
Remote control facilities ........................................................................ 12
4.4
Monitoring facilities ................................................................................ 13
4.5
Torque and limits ................................................................................... 14
4.6
Manual override system ........................................................................ 14
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SPAN TS 1701:2015
1.0
Scope
This specification covers the requirements of electric actuator for valves and
penstocks. Mechanical type electrical actuator is the minimum type of actuator
required to be provided. Digital type electric actuator shall be provided when valve
modulating is required.
2.0
Common specification for electric actuator
2.1
General
The actuators shall be suitable for use on a nominal 415 V, 3 phase, 50 Hz power
supply and are to incorporate motor, integral reversing starter, local control facilities
and terminals for remote control and indication connections housed within a selfcontained, sealed enclosure.
As a minimum the actuators should meet the requirements set out in EN15714-2.
Necessary commissioning tools shall be provided if required. The actuator shall
include a device to ensure that the motor runs with the correct rotation for the
required direction of valve travel irrespective of the connection sequence of the
power supply.
2.2
Actuator sizing
The actuator shall be sized to guarantee valve closure at the specified differential
pressure and temperature. The safety margin of motor power available for seating
and unseating the valve shall be sufficient to ensure torque switch trip at maximum
valve torque with the supply voltage 10% below nominal. For linear operating
valves, the operating speed shall be such as to give valve closing and opening at
approximately 10-12 inches (200 to 300mm) per minute unless otherwise stated in
the data sheet. For 90 degree valve type the operating time will be specified.
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SPAN TS 1701:2015
2.3
Environmental
Actuators shall be suitable for indoor and outdoor use.
The actuator shall be
capable of functioning in an ambient temperature ranging from -30°C (22°F) to 70°C
(140°F), up to 100% relative humidity. Actuators for hazardous area applications
shall
meet
the
area
classification,
gas
group
and
surface temperature
requirements specified in data sheet.
2.4
Enclosure
Actuators shall be o-ring sealed, watertight to IP66/IP68 7m for 72hrs, NEMA 4, 6.
The motor and all other internal electrical elements of the actuator shall be
protected from ingress of moisture and dust when the terminal cover is removed for
site for cabling, the terminal compartment having the same ingress protection rating
as the actuator with the terminal cover removed. The material of the casting shall be
Aluminium Alloy or equivalent.
Enclosure must allow for temporary site storage without the need for electrical
supply connection. All external fasteners shall be plated stainless steel or equivalent.
The use of un-plated stainless steel or steel fasteners is not permitted.
2.5
Motor
The motor shall an integral part of the actuator, designed specifically for valve
actuator applications.
It shall be a low inertia high torque design, class F
insulated with a class B temperature rise giving a time rating of 15 minutes at
40°C (104°F) at an average load of at least 33% of maximum valve torque.
Electrical and mechanical disconnection of the motor should be possible without
draining the lubricant from the actuator gear case.
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SPAN TS 1701:2015
2.6
Motor protection
Protection shall be provided for the motor as follows:
a. Stall – the motor shall be de-energized within 8 seconds in the event of a stall
when attempting to unseat a jammed valve.
b. Over temperature – thermostat will cause tripping of the motor. Auto-reset on
cooling.
c. Single phasing – lost phase protection.
d. Direction – phase rotation correction.
2.7
Gearing
The actuator gearing shall be totally enclosed in an oil-filled o r grease-filled gear
case suitable for operation at any angle. Grease lubrication is only permissible for
quarter-turn actuator. All drive gearing and components must be of metal
construction and incorporate a lost-motion hammerblow feature. For rising spindle
valves the output shaft shall be hollow to accept a rising stem, and incorporate
thrust bearings of the ball or roller type at the base of the actuator. The design
should be such as to permit the opening of the gear case for inspection or
disassembled without releasing the stem thrust or taking the valve out of service.
All actuator shall be self-locking to prevent the valve back-driving the actuator.
2.8
Hand operation
A hand wheel shall be provided for emergency operation, engaged when the motor
is declutched by a lever or similar means, the drive being restored to electrical
operation automatically by starting the motor. The hand wheel or selection lever
shall not move on restoration of motor drive.
Provision shall be made for the
hand/auto selection lever to be locked in both hand and auto positions. It should be
possible to select hand operation while the actuator is running or start the actuator
motor while the hand/auto selection lever is locked in hand without damage to the
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SPAN TS 1701:2015
drive train. Clockwise operation of the hand wheel shall give closing movement
of the valve unless otherwise stated in the data sheet. For linear valve types the
actuator hand wheel drive must be mechanically independent of the motor drive and
should be such as to permit valve operation in a reasonable time with a manual
force not exceeding 400N through stroke and 800N for seating/unseating of the
valve. The material for hand wheel shall be a minimum from marine alloy (BS 1490,
LM5M) or equivalent.
2.9
Drive interface
The actuator shall be furnished with a drive bushing easily detachable for machining
to suit the valve stem or gearbox input shaft. The drive bush shall be positioned in a
detachable base of the actuator. Thrust bearings shall be sealed for life and the
base shall be capable of withstanding five times the rated thrust of the actuator.
2.10 Local controls
The actuator shall incorporate local controls for Open, Close and Stop and a
Local/Stop/Remote mode selector switch lockable in any one of the following
three positions: local control only, stop (no electrical operation), remote control
plus local stop only. It shall be possible to select maintained or non-maintained
local control.
The local controls shall be arranged so that the direction of valve travel can be
reversed without the necessity of stopping the actuator. The local controls and
display shall be rotatable through increments of 90 degrees to suit valve and
actuator orientation.
2.11 Integral starter and transformer
The reversing starter, control transformer and local controls shall be integral with the
valve actuator, suitably housed to prevent breathing and condensation. The starter
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SPAN TS 1701:2015
shall be suitable for 60 starts per hour and of rating appropriate to motor size. The
controls supply transformer shall be fed from two of the incoming three phases and
incorporate overload protection. It shall have the necessary tapping and be
adequately rated to provide power for the following functions:
a. Energising of the contactor coils
b. 24V DC or 110V AC output for remote controls (maximum 5W/VA)
c. Supply for all the internal electrical circuits
2.12 Wiring and termination
Internal wiring shall be tropical grade PVC insulated stranded cable of appropriate
size for the control and 3-phase power. Each wire shall be clearly identified at each
end.
The terminals shall be embedded in a terminal block of high tracking
resistance compound.
The terminal compartment shall be separated from the inner electrical components
of the actuator by means of a watertight seal and shall be provided with a minimum
of 3 threaded cable entries with provision for an additional 5 extra conduit entries.
All wiring supplied as part of the actuator to be contained within the main enclosure
for physical and environmental protection. External conduit connections between
components are not acceptable. A durable terminal identification card showing a
plan of terminals shall be provided attached to the inside of the terminal box cover
indicating:
a. Serial number
b. External voltage values
c. Wiring diagram number
d. Terminal layout
The code card shall be suitable for the contractor to inscribe cable core
identification alongside terminal numbers.
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SPAN TS 1701:2015
2.13 Commissioning kit
Each actuator shall be supplied with a start-up kit comprising installation instruction
manual, electrical wiring diagram and cover seals to make good any site losses
during the commissioning period.
In addition, sufficient actuator commissioning
tools shall be supplied to enable actuator set up and adjustment during
valve/actuator testing and site installation commissioning.
2.14 Performance and test certificate
Each actuator must be performance tested and individual test certificates shall be
supplied free of charge. The test equipment should simulate a typical valve load,
and the following parameters should be recorded.
a. Current at maximum torque setting
b. Torque at maximum torque setting
c. Flash test voltage
d. Actuator output speed or operating time
In addition, the test certificate should record details of specification such as
gear ratios for both manual and automatic and second stage gearing if provided,
drive closing direction, wiring diagram number.
2.15 Safety protection
The actuator shall equip with following safety protection features:
a. Over current protection
Actuators will stop the motor automatically in case of over current.
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b. Emergency shutdown ESD
A configured action will override any active signals in the event of an emergency
to prevent any loss. The action is configured by the customer beforehand.
Specifications for the mechanical and digital type electric actuators are stipulated in
sections 3.0 and 4.0 respectively.
3.0
Mechanical type electric actuator
3.1
Remote valve position/actuator status indication
Open/Close limit switches shall be provided for remote indication of valve position,
with each contact rated at 5A, 250V AC, 30V DC. The limit switches shall be
mechanically activated to ensure availability of remote indication even when doing
hand operation of the actuator during a power outage. Actuator that requires the use
of a battery to update the positioning of the actuator during main power outage shall
not be used. In addition to the above, the design for the addition of a position
transmitter to give a 4-20mA analogue signal corresponding to valve travel for remote
indication shall be provided.
Position limit switches shall be fully adjustable over the full range of valve travel.
When mechanical position limit switches are used for external indication, the
appropriate contacts shall open at their preset limits of travel. They shall function
identically when the actuator is operated by motor or hand wheel. Position limit
switches shall be set by the valve manufacturer or actuator supplier during mounting
adaptation of actuator to the valve at the valves manufacturer'
s or actuator supplier
shop.
As an alternative to providing valve position indication , contacts shall be
provided for following signal:
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SPAN TS 1701:2015
a. Thermostat tripped, lost phase
b. Motor tripped on torque in mid travel, motor stalled
c. Remote selected
3.2
Local position indication
A mechanical dial indicator shall be provided to show open / intermediate / close
position of the valve.
3.3
Remote control facilities
The necessary control, wiring and terminals shall be provided integral to the
actuator enclosure. Open and close external interlocks shall be made available
to inhibit local and remote valve opening / closing control. It shall be possible to
configure the interlocks to be active in remote control only. Remote control signals
fed from an internal 24V DC (or 110VAC) supply and/or from an external supply
between 20V and 60V DC or 40V and 120V AC, to be suitable for any one or
more of the following methods of control:
a. Open, Close and Stop control.
b. Open and Close maintained or “push to run” (inching) control.
c. Overriding Emergency Shut-down to close (or open) valve from a normally
closed or open contact.
d. Two-wire control, energise to close (or open), de-energise to open (or close).
Additionally provision shall be made for a separate ‘drive enable’ input to
prevent any unwanted electrical operation. It shall be possible to reverse valve
travel without the necessity of stopping the actuator. The motor starter shall be
protected from excessive current surges during rapid travel reversal.
The internal circuits associated with the remote control and monitoring functions are
to be designed to withstand simulated lightning impulses of up to 2kV.
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SPAN TS 1701:2015
3.4
Monitoring facilities
Facilities shall be provided for monitoring actuator operation and availability as
follows:
Actuator text display indication of the following status/alarms:
a. Control selector set to local/stop
b. Termostat trip
c. Main/internal power supply failure
3.5
Torque and limits
Torque switches shall be adjustable from 40% to 100% of the maximum torque of
the actuator to protect the motor.
4.0
Digital type electric actuator
4.1
Remote valve position and status indication
At least four contacts shall be provided which can be selected to indicate any
position of the valve; Provision shall be made for the selection of a normally closed
or open contact form. Contacts shall maintain and update position indication during
hand wheel operation when all external power to the actuator is isolated. The
contacts shall be rated for 5mA to 5A, 120V AC, 30V DC.
Position limit switches shall be fully adjustable over the full range of valve travel.
When mechanical position limit switches are used for external indication, the
appropriate contacts shall open at their preset limits of travel. They shall function
identically when the actuator is operated by motor or hand wheel. Position limit
switches shall be set by the valve manufacturer or actuator supplier during mounting
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SPAN TS 1701:2015
adaptation of actuator to the valve at the valves manufacturer'
s or actuator supplier
shop.
As an alternative to providing valve position indication any of the above
contacts shall be selectable to signal one of the following:
a. Valve opening, closing or moving
b. Thermostat tripped, lost phase
c. Motor tripped on torque in mid travel, motor stalled
d. Remote selected
e. Actuator being operated by hand wheel
f.
Actuator fault
Provision shall be made in the design for minimum additional eight contacts
having the same functionality.
Provision shall be made in the design for the addition of a contactless transmitter to
give a 4-20mA analogue signal corresponding to valve travel and/or torque for
remote indication when required. The transmitter will auto range to the set limits
In order to maintain the integrity of the enclosure, setting of the torque levels,
position limits and configuration of the indication contacts etc. shall be carried out
without the removal of any actuator covers and without mains power over an Infrared, Bluetooth or equivalent wireless interface. Necessary commissioning tools shall
be provided if required. Provision shall be made to disable wireless communications
or only allow a wireless connection initiated by an Infra-Red or equivalent command
for maximum security.
4.2
Local position indication
The actuator display shall include a dedicated numeric/symbol digital position
indicator displaying valve position from fully open to fully close in 0.1% increments.
Valve closed and open positions shall be indicated by symbols showing valve
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SPAN TS 1701:2015
position in relation to the pipe work to ensure that valve status is clearly interpreted.
With mains power connected, the display shall be backlit to enhance contrast at all
ambient light levels and shall be legible from a distance of at least 5m (16ft).
Red, green, and yellow LEDs corresponding to open, closed and intermediate valve
positions shall be included on the actuator display when power is switched on. The
yellow LED should also be fully programmable for on/off, blinker and fault indication.
The digital display shall be maintained and updated during hand wheel operation
when mains power to the actuator is isolated.
The actuator display shall include a fully configurable dot-matrix display element
with a minimum pixel resolution of 168 x 132 to display operational, alarm,
configuration and graphical data logger information.
Provision shall be made to
upload a different language without removal of any covers or using specialized tools
not provided as standard with the actuator.
In the event when the battery has been discharge, the electric actuator can still
capture the positioning if manual override is done during power outage; without the
need to reset the actuator positioning.
Data logger graphical displays should as a minimum be able to display log and
trend graphs on the local LCD for the following:
a. Torque versus Position
b. Number of Starts versus Position
c. Number of starts per hour
d. Dwell Time
e. Average temperature
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SPAN TS 1701:2015
The main display shall be capable of indicating 4 different home-screens of the
following configuration:
a. Position and status
b. Position and torque (analogue)
c. Position and torque (digital)
d. Position and demand (positioning)
Provision shall be made for the addition of an optional environmental cover to
protect the display from high levels of UV radiation or abrasive materials.
The local controls and display shall be rotatable through increments of 90 degrees
to suit valve and actuator orientation.
4.3
Remote control facilities
The necessary control, wiring and terminals shall be provided integral to the
actuator enclosure. Open and close external interlocks shall be made available
to inhibit local and remote valve opening / closing control. It shall be possible to
configure the interlocks to be active in remote control only. Remote control signals
fed from an internal 24V DC (or 110VAC) supply and/or from an external supply
between 20V and 60 VDC or 40V and 120VAC, to be suitable for any one or
more of the following methods of control:
a. Open, Close and Stop control.
b. Open and Close maintained or “push to run” (inching) control.
c. Overriding Emergency Shut-down to close (or open) valve from a normally
closed or open contact.
d. Two-wire control, energise to close (or open), de-energise to open (or close).
Additionally provision shall be made for a separate ‘drive enable’ input to
prevent any unwanted electrical operation. It shall be possible to reverse valve
travel without the necessity of stopping the actuator. The motor starter shall be
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SPAN TS 1701:2015
protected from excessive current surges during rapid travel reversal. The internal
circuits associated with the remote control and monitoring functions are to be
designed to withstand simulated lightning impulses of up to 2kV.
Provision shall be made for operation by distributed control system utilising the
following network systems or equivalent:
a. Profibus
b. Modbus
c. Foundation Fieldbus
d. Pakscan (wired and wireless)
e. HART
4.4
Monitoring facilities
Facilities shall be provided for monitoring actuator operation and availability as
follows:
Actuator text display indication of the following status/alarms:
a. Closed Limit, open limit, moving open, moving closed, stopped
b. Torque trip closing, torque trip opening, stalled
c. ESD active, interlock active
d. Thermostat trip, phase lost, 24V supply lost, Local control failure
e. Configuration error, Position sensor failure, Torque sensor failure
f.
Battery low, power loss inhibit
Integral data logger to record and store the following operational data:
a. Opening last /average torque against position
b. Closing last /average torque against position
c. Opening motor starts against position
d. Closing motor starts against position
e. Total open/closed operations
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f.
Maximum recorded opening and closing torque values
g. Event recorder logging operational conditions (valve, control and actuator)
The data logger shall record relevant time and date information for stored data. Data
logger data shall be accessed via non-intrusive Bluetooth communication or
equivalent and data displayed on the local LCD. Sufficient standard intrinsically
safe tools shall be provided for downloading data logger and actuator configuration
files from the actuators and subsequent uploading to a PC. The actuator
manufacturer shall supply PC software to enable data logger files to be viewed and
analysed.
4.5
Torque and limits
Torque switches shall be adjustable from 40% to 100% of the maximum torque of
the actuator. Absolute position measurement should be incorporated within the
actuator. The technology must be capable of reliably measuring position even in the
case of a single fault. The design must be simple with the minimum amount of
moving parts (no more than 5).
4.6
Manual override system
The manual override system shall be designed in such a way that the actuator limits
will not need to be reset if manual operation is performed during loss of both main 3
phase power and battery back-up power. The actuator shall be able to operate
normally when power supply is restored without the need to reset the limits.
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