NUMALIGARH
REFINERY
LIMITED
Technical Specification For
Motor Operated Valve
Unit: DCU
Page 1 of 10
CONTENTS
1.0
SCOPE
2.0
DATA SHEET FOR MOV ACTUATOR
3.0
DETAIL SCOPE FOR ELECTRICAL ACTUATOR
4.0
INSTRUMENTATION REQUIREMENTS
5.0
COMMISSIONING
1.0
Scope
This specification shall be read in conjunction with NRL technical specification for procurement of
valves
(No.
MM/Tech/02/2010).
This
specification
covers
details
towards
electrical
and
instrumentation items only. All standards mentioned in this specification shall invariably be the
latest edition / revision. In case of any deviation the bidder is advised to use the deviation sheet
attached with document MM/Tech/02/2010. In absence of any deviation sheet it will be assumed
that bidder accepts all conditions mentioned in this specification. The bidder shall enclose a signed
copy of this page as a token of acceptance of all clauses appearing in this specification.
2.0
DATA SHEET FOR MOV ACTUATOR
Part –I: NRL DATA
1.0
Site Conditions
1.1
Altitude
:
Les than 1000 m
1.2
Design ambient temperature
:
40oC
1.3
Humidity
:
Highly humid
1.4
Climate
:
Highly dusty, corrosive as prevalent in a
refinery
1.5
Project site
:
Delayed Coker Unit
1.6
MOV Tag No.
:
03-MOV-1401, 03-MOV-1402
2.0
System Conditions
2.1
Supply voltage
:
415V + 10%, 3-phase AC
2.2
Supply frequency
:
50HZ + 3%
2.3
System earthing
:
Solidly earthed
3.0
Operating Environment
3.1
Area Classification
:
Zone 2
3.2
Gas Group
:
IIA/ IIB
3.3
Temperature Class
:
T3
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Technical Specification For
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Unit: DCU
Page 2 of 10
3.4
Construction
:
Flameproof Ex (d)
3.5
Ingress Protection
:
IP65
3.6
Painting
:
Epoxy base
3.7
Whether ‘K Mass’ type or equivalent
fireproofing required
:
Yes
3.7.1 For MOV Tag Nos.
:
Both
3.7.2 With Fireproof rating
:
30 minutes
4.0
Valve Duty, Mode of Control and Device for Control
4.1
Valve duty
a. Fully open and fully closed
:
Yes
b. Partially open and partially closed
:
4.2
Control requirement
:
Local & Remote for all MOV’s
4.3
Local/ Remote/ Off selector switch
on MOV Actuator
:
Required
4.4
Compatibility for interfacing with 2 wire
control system
:
Required
4.5
Setting of adjustable parameters of Actuator
(For 2 wire control system)
:
NA
4.6
Continuous of position indication
4.6.1 Local
:
Mechanical/ LCD indication required
4.6.2 Remote – Potentiometer/ transducer for
remote continuous indication
:
Required
4.7
Intermediate travel limit switch
:
Not required for all MOV’s
4.8
Potential free contacts for indication on
remote panel and other interlocks
:
4.8.1 For valve open position
:
Required
4.8.2 For valve closed position
:
Required
4.8.3 For remote indication of position of local/
Remote selector switch
:
Required
4.8.4 For availability of MOV actuator for remote
Operation (contact from monitoring relay)
:
Required
4.8.5 For indication valve operation in progress
:
Required
4.9
Remote Emergency Stop push button for
stopping actuator
:
Required
4.10
DCS interface for Remote control/ indication
:
Remote Control requirement shall be as
per CI.4.2 above/ Remote indication
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4.11
Technical Specification For
Motor Operated Valve
Unit: DCU
Page 3 of 10
Maximum time of operation
- Opening
:
As per Valve data sheet
- Closing
:
As per Valve data sheet
4.12
Double compression cable glands and plug for
unused entries (To be supplied along with MOV
actuator)
:
Flameproof & WP type
4.13
Make of MOV Actuator
:
Rotork
5.0
Test and Approval Certificates for Flameproof Actuators
5.1
For Indigenous make MOV Actuators
:
Yes
5.2
For Imported make MOV Actuators
:
Yes
5.3
Submission of Type test certificates
:
Yes
6.0
Applicable NRL Specification
6.1
Specification for electrical motor operated
:
Yes
Valve actuators
7.0
Special Requirements
:
Both Soft and Hard copy of the following documents required1. Operation and maintenance manual of MOV
2. BOM of MOV
3. General arrangement (GA) drawing of MOV
4. Circuit diagram of MOV
NOTES:
1.
NA denotes ‘Not Applicable’.
2.
Area Classification Zone, Gas Group and Temperature class indicated at S. no. 3.1 to 3.3 above
refer to IS/ IEC standards.
3.
The purchaser shall provide single point supply to the actuator as per S. No. 2.0 above. Any other
control supply voltage required shall be internally derived by the manufacturer within the actuator.
4.
In case ‘Remote continuous position indication’ is required as per S. No. 4.6.2 above, the
potentiometer/ transducer required for position indication along with loose remote continuous
position indicator shall be included in the quoted prices of respective MOV Actuator and supplied
with it.
5.
Vendor shall furnish complete data as per Part-II of this data sheet for each MOV actuator along
with the offer.
6.
Remote Input signals for Opening/Closing/Stopping the MOV shall be provided through the
momentary closing of separate potential free contacts in owner’s panel. Necessary controls
required for running the motor for the complete opening/ closing sequence of the valve using such
input signals shall be provided by manufacturer in the actuator.
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Technical Specification For
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Unit: DCU
Page 4 of 10
7.
Vendor shall quote for Maintenance spares for two years trouble free operation and maintenance of
the MOV actuators indicating recommended quantity and unit prices.
8.
Vendors shall include the complete set of commissioning spares (spares which would be necessary
during commissioning of the actuator and associated hardware, as envisaged by vendor) along with
the offered actuator. Vendor shall quote the price of commissioning spares with a list of such
spares.
9.
Two separate earthing bosses shall be provided for all the actuators for carrying out the double
earthing.
10.
MOV’s shall be provided with min. 4 nos. entries.
11.
Double compression cable glands & 1 no. Flameproof plug shall be provided for each MOV.
12.
Any special tools/tackles for commissioning of MOV’s with two wire control system shall be supplied
by vendor, along with actuators.
SPECIAL REQUIREMENT FOR MOVs
1. a.
Bidder shall provide filled in Data sheet for torque values of MOVs. Torque values submitted
for MOVs shall be in line with the following requirements i.e.
- Valve break and running torque figures with a safety factor of 1.5 shall be minimum 1.5
times the break and running torque values.
- Actuator generated break and running torque shall be minimum equal to or greater than
the break and running values with a safety factor of 1.5 respectively.
- The actuator break and running torque shall be less than the maximum allowable valve
stem torque.
b.
The functional test of complete assembly of MOVs along with the actuator and control system
shall be performed by the supplier at works in presence of owner/ Owners representative.
2.
Valve with motorized actuator shall be suitable for installation in horizontal/vertical lines.
3.
MOVs to be operable from field and control room.
4.
Bidder shall be solely responsible for selection of suitable actuators & actuator control system.
Vendor shall also be single point responsible for the complete system.
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Technical Specification For
Motor Operated Valve
Unit: DCU
Page 5 of 10
Part –II: DATA FROM VENDOR
DATA SHEET FOR MOV ACTUATOR
1.0
ACTUATOR
1.1
Make
1.2
Type & Catalogue
1.3
Applicable Wiring Diagram No.
1.4
Valve Duty
1.5
Max. Permission No. of
Open / Close cycles per hour
1.6
Internal Control supply used in Actuator
1.7
Recommended Back up HRC fuse rating (Control)
Recommended Back up HRC fuse rating (Power)
Power fuse not provided in the actuator
1.8
2.0
Time in sec. for fully opening / closing
MOTOR
2.1
Make
2.2
Kw rating
2.3
Rated speed in RPM
2.4
Enclosure
2.5
Locked rotor (Starting) current
2.6
Rated torque current
2.7
Average load current
3.0
BASIS FOR SIZING AND SELECTION OF ACTUATOR
4.0
TEST AND APPROVAL CERTIFICATES
5.0
COMPONENTS MAKE
5.1
Contactors
5.2
Push Buttons
5.3
Selected Switches
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3.0
Technical Specification For
Motor Operated Valve
Unit: DCU
Page 6 of 10
DETAIL SCOPE FOR ELECTRICAL ACTUATOR
This section covers design, manufacturer, assembly, shop testing and supply of electrical motor
operated valve actuators intended for fully / partially opening and closing valve duty.
3.1
CODES AND STANDARDS
1. The equipment shall comply with the requirement of latest revision of the following standards
issued by BIS (Bureau of Indian Standard) unless specified otherwise.
IS 5
Colours for ready mixed paints and enamels.
IS 325
Three-phase Induction Motors.
IS 2148
Flameproof enclosures for electrical apparatus.
IS 4691
Degrees of protection provided by enclosure for rotating electrical machinery.
IS 4722
Rotating electrical machines – Specification
IS 9334
Electric Motor Operate Actuators
IS 13947
Low voltage Switchgear and Control gear
2. In case of imported equipment, the standards of the country of origin shall be applicable if
these standards are equivalent or more stringent than the applicable Indian standards.
3. The equipment shall also conform to the provision of Indian Electricity Rules and other statutory
regulations currently in force in the country.
4. In case Indian Standards are not available for any equipment, standards issued by IEC/ BS/
VDE/ IEEE/ NEMA or equivalent agency shall be applicable.
5. In case of any contradiction between various referred standards/ specifications/ data sheets
and statutory regulations, the following order of decreasing priority shall govern:
3.2
-
Statutory regulations
-
Data sheets
-
Job specifications
-
This specification
-
Codes and standards
GENERAL REQUIREMENTS
1. This offered equipment shall be brand new with state of the art technology with a proven field
track record. No prototype equipment shall be offered.
2. Vendor shall ensure availability of spare parts and maintenance support services for the offered
equipment for at least 15 years from the date of supply.
3. Vendor shall give a notice of at least one year to NRL before phasing out the product/ spares to
enable NRL to place order for spares and services.
4. The vendor shall be responsible for design, engineering and manufacturing of the complete
actuator to fully meet the intent and requirements of this specification and attached data
sheets.
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3.3
Technical Specification For
Motor Operated Valve
Unit: DCU
Page 7 of 10
POWER SUPPLY
The electrical motor operated valve actuators shall be suitable for power supply at 415V + 10%,
50Hz + 3%, 3 phase, unless specified otherwise in the data sheet.
3.4
TECHNICAL SPECIFICATIONS
Each MOV actuator shall include the motor, actuator unit, gears, position indicators, limit switches,
hand wheel, electrical starter and controls, terminal box etc. as a self-contained unit. The actuator
shall be provided adequate torque and/ or thrust to ensure the complete intended travel of the
valve under the worst operating and electrical power supply conditions.
3.4.1. Motor
1. The motor shall be 3-phase squirrel cage induction type unless specified otherwise in the data
sheet. It shall have totally enclosed non-ventilated construction.
2. The motor shall be designed for valve actuator service with high starting torque and shall be
suitable for direct on-line starting. It shall be rated for S2-15 minute duty and shall conform to
IS 325 or equivalent international standards.
3. The motor shall be provided with thermostat(s)/ thermister(s)/ embedded in the hot spots of
motor winding for protecting the motor.
4. The motor shall be able to operate the actuator at 75% of rated voltage.
5. The motor shall have class ‘F’ insulation with temperature rise limited to class ‘B’ limits. Motor
winding shall be treated to resist corrosive agents and moisture.
6. Motor rotor shall preferably be of die-cast aluminium and, if brazed, shall be free from
phosphorous.
3.4.2 Integral Starter and Control Transformer
The reversing starter, control transformer and local controls shall be integral with the valve
actuator, unless specified otherwise in the data sheet. Solid state control of valve actuator and
electrically isolated interface for remote control requirement shall be provided, wherever these
features exist in manufacturer’s design.
The integral starter shall be supplied with the following device:
a)
Electrically and mechanically interlocked reversing contractors for opening and closing
operations.
b)
Control transformer with necessary tapping and protected with suitable easily replaceable
uses.
c)
Terminal block for external cable connection fully rewired for internal devices of valve
actuator.
MOV Actuator operating with AC power supply shall be provided with instantaneous Phase reversal
protection.
3.4.3 Integral Push Button, Selector switches, Indications and Control devices
The following local control devices shall be provided integral with the MOV actuator:
a)
Push buttons for ‘Opening/ Closing/ Stop’ or alternatively ‘Open/ Close’ selector switches.
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Technical Specification For
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Unit: DCU
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b)
‘Local/ Off/ Remote’ selector switch, pad-lockable in each position.
c)
Local continuous position indication from ‘Valve fully open’ to ‘Valve fully closed’ position,
which may be of analogue or digital type using mechanical indication/ Indicating lamps/
LEDs.
d)
Push button operation should be such that the action required for opening is different from
action required for closing (e.g. Pull Type and Push Type)
3.4.4 Torque and Travel Limit Switches
Torque limit switches shall be provided to protect the motor from over-loading by cutting off the
power supply to motor during opening and closing operations. The limit switches shall be preset.
However, it shall be possible to set the value of maximum torque during closing from 50% to 100%
of rated torque of actuators. Travel limit switch shall be provided to cut-off the power supply to the
motor at the end of preset limit of valve travel. The switches shall be provided with requisite
number of potential-free contacts for valve actuator operation and for indication on remote panels
as specified in data sheet. Instead of mechanical torque limit switches, magnetic pulse counter to
measure and control the stroke of actuator may be provided, wherever this feature exists in
manufacturer’s design.
3.4.5 Control Facilities
The internal controls and monitoring circuits shall be incorporated within the integral starter along
with transformer and control unit of valve actuator.
Remote control facility shall be provided, if specified in the data sheet. The remote control circuits
shall be powered from internally derived control supply voltage, unless the use of external supply
for remote control is specified in data sheet. In order to cater to remote control and indication
requirements for ‘Position of Remote/ Local/ Off selector switch’, if specified in the data sheet, an
additional Monitoring relay/ auxiliary/ relays shall be provided as a part of the valve actuator. As an
alternative, a common status contact indicating the availability of the MOV actuator for remote
control may be provided by monitoring the following:
-
Loss of one or more phases of power supply.
-
Loss of control circuit supply
-
Selector switch in local mode
-
Local stop push button set of ‘Off’
-
Motor thermostat tripped
-
Any other local fault/ abnormal condition
3.4.6 Hand Operation
A hand wheel with hand/ auto lockable lever shall be provided for emergency operation of the
MOV. The energisation of the motor shall automatically re-engage power operation.
3.4.7 Remote Position Indicator
If specified in the data sheet, a 4-20 mA remote position transmitter shall be provided in the valve
actuator and a continuous position indicator for mounting in purchaser’s remote panel shall be
supplied as a loose item. The remote position indicator shall continuously indicate the position of
travel f the valve.
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Technical Specification For
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3.4.8 Nameplate
Each motorized valve actuator shall be provided with a stainless steel nameplate furnishing the
following details, attached firmly to it at a place convenient for reading:
a) Actuator tag number as per data sheet.
b) Motor kW rating, motor time rating, motor supply voltage, nominal motor phase current,
auxiliary switch rating.
c) Maximum torque setting
d) Actuator enclosure type, lubricant type
e) Actuator type, wiring diagram number/ catalogue number, actuator serial number.
A separate nameplate shall be provided for hazardous area application.
3.4.9
The enclosure of complete MOV actuator including motor, integral starter, control transformer unit
and all control devices shall have minimum IP-65 degree of ingress protection.
3.4.10 Wiring and Terminals
All devices provided in the actuator shall be wired up to the terminal block. The contacts for remote
operation and indication shall also be wired up to the terminal block. Minimum 10% spare
terminals shall be provided for future interlocks. Internal wiring for power and control circuits shall
be appropriately sized for MOV actuator rating. Each wire shall be identified at both ends using PVC
ferrules. The terminal compartments shall be separated from the inner electrical components of the
actuator by means of a watertight seal so that the actuator electrical components are protected
from the ingress of moisture and foreign materials when the terminal cover is removed during
installation and maintenance.
3.4.11 Vendor shall be responsible for the compatibility of the MOV actuator with the valve and for the
selection and sizing of various electrical devices and components in the actuator.
3.4.12 The actuator shall be provided with maximum three adequately sized cable entries viz., one for
power cable and two for control cables. Suitable double compression cable glands shall be provided
with each actuator for all cable entries and sealing plugs for all control cable entries. The cable
glands and plugs shall be made of Nickel-plated brass.
3.5
EQUIPMENT FOR CALSSIFIED HAZARDOUS AREAS
3.5.1 Actuators meant for hazardous areas shall meet the requirements of IS 2148, IEC 79 or equivalent
international standards and shall be suitable for Gas groups and Temperature class as specified in
the data sheet. The manufacturer shall possess valid test certificates issued by a recognized
independent test house (CMRI/ BASSEEFA/ LCIE/ UL/ FM or equivalent) for the offered actuators.
All indigenous equipment shall conform to Indian standards and shall have been tested and
certified by Indian testing agencies. All equipment indigenous and imported) shall also have valid
statutory approvals as applicable for the specified hazardous locations from CCE or any other
applicable statutory authority. All indigenous flameproof equipment shall have valid BIS license and
corresponding marking as required by statutory authorities.
3.5.2 Apart from the nameplate indicating the Tag No., a separate nameplate shall also be provided on
each actuator to indicate the details of the testing agency (CMRI or equivalent), test certificate
Mechanical Maintenance Department
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number with date, statutory approval number with date, approval agency (CCE/ DGMS or
equivalent), BIS license number with date, applicable Gas group and Temperature class etc. The
nameplate shall be riveted/ fixed with screws and not pasted. In case any of the standard details
listed above are embossed on the enclosures, the same need not be repeated.
3.6
FIREPROOFING
3.6.1 If specified in the Data Sheet, the MOV Actuators shall be provided with ‘K-Mass’ type or equivalent
fireproofing. Unless specified otherwise, the fireproofing shall be rated for 30 minutes. The required
certificates for the fireproof rating shall be furnished from an independent test laboratory.
3.6.2 MOV Actuators with fireproofing shall be suitable for termination of mica insulated fire survival type
power and control cables.
3.7
INSPECTION, TESTING AND ACCEPTANCE
The equipment shall be subject to inspection by NRL or by an agency authorized by the owner.
Manufacturer shall furnish all necessary information concerning the supply to NRL. During the
course of manufacturing, NRL or other authorized representative shall be free to visit the works
and assess the progress of work and the manufacturer shall render him all possible assistance to
do so. The vendor shall include all relevant tests for actuator including complete MOV testing in
their QAP as per MM/Tech/02/2010. Type test certificates shall be furnished with bids. Final
acceptance of MOVs at site shall be subject to successful testing of the MOV actuators with the
valves. Type test certificates, original drawings referred in certificates and statutory approval
certificates and BIS license, where applicable, shall be shown to the inspection agency on demand.
The certificates and BIS license must be valid at the time of dispatch.
3.8
PACKING AND DESPATCH
The equipment may be stored outdoors for long periods before installation. The packing shall be
completely suitable for outdoor storage in areas with heavy rains and high ambient temperature
unless otherwise agreed. In order to prevent movement of equipment/ components within the
crates, proper packing supports shall be provided. A set of instruction manuals for erection, testing
and commissioning, a set of operation and maintenance manuals and a set of final drawings shall
be enclosed in a waterproof cover along with the shipment.
4.0
INSTRUMENTATION REQUIREMENTS
4.1
Remote open/close command from control room to MCC (of MOV) of electrical substation:
Instrumentation will provide Potential free contact (using non latching push button) to electrical
MCC of the MOV and the interposing/control voltage (not greater than 230 VAC/DC) will be from
the electrical MCC of the MOV.
4.2
Fully open/ close feed back indication to control room:
For fully open / close indication Instrumentation need potential free contact from the electrical
MCC/ MOV for fully open indication. The interposing/control voltage (not greater than 110VAC) will
be from NRL control system (DCS/PLC).
5.0
COMMISSIONING
The vendor shall depute a commissioning engineer for commissioning of the valve with MOV. The
payment shall be released only after successful site acceptance test.
Mechanical Maintenance Department