Annexure-B

TECHNICAL SPECIFICATIONS
VALVE ACTUATORS
1. SCOPE

1.1 Valve actuators supplied in accordance with this specification shall be quarter-
turn type, suitable for operation (Open/Close) of plug valves.
1.2 The actuators shall be Pneumatic or Gas-Over-Hydraulic type with Scotch-Yoke
mechanism for force transmission, designed for maximum reliability / durability
and fully fit for outdoor installation / service.
1.3 Pneumatic actuator shall consist of Pneumatic motor, tank, Gas regulation,
filtration, scotch-yoke mechanism, control unit and manual override.
1.4 Gas-over-Hydraulic actuator shall consist of Gas-over-hydraulic tanks, scotch-
yoke mechanism, gas filtration, hydraulic control valves, control unit and manual
override.
2. ACTUATOR COMPONENTS

2.1 Scotch-Yoke-Operator with double acting hydraulic cylinders.

2.2 Actuator Control system consisting of a double 3-way, 2 position control valve,
piloted by single solenoid valve for the remote control opening and closing
operation. These valves are to be equipped with 2 levers one for opening and one
for closing for local operation.
2.3 Junction box, where all the wiring originating from the actuator electric
components and from the remote control panels are connected Junction box to be
equipped with local / remote selector.
2.4 Hydraulic hand pump for manual override, equipped with flow control valves and
manual directional control valves.
2.5 Gas-over-oil Tanks for Gas-over-Hydraulic actuators.
2.6 Pneumatic power module and gas storage tank for Pneumatic actuators.
2.7 Micro switch housing containing travel limit switches necessary for signaling
valve position and de-energizing the solenoid valve.
2.8 Filtration and drain system for supply of gas to the actuator along with relief and
shuttle valves.
2.9 Provision for future addition of line break device and ESD device in the control
unit.
2.10 The actuator should be designed to operate with pneumatic motor driven
hydraulic pump (power pack), the motor shall be operated with available Natural
Gas / Air supply of 100-185 psig. The power pack should be mounted directly on
the actuators.
2.11 Maximum operating time shall be 2 – 5 seconds and shall be adjustable.
2.12 All pressure regulators equipped with full flow relief valve to protect the system
in case of regulator failure, shall be supplied. Filters, condensate separators,
lubricators and breather should be provided with actuators.
2.13 Explosion proof Electrical limit switch pack designed for Class 1, Division 1,
Group D serviced, consisting of at least 2 No. switches, one for fully close and

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 other for fully open positions of the valve. Each switch shall have from C type
contacts i.e. normally open, normally close and common. These switches shall
work on 24 VDC systems and shall be capable for carrying 3 Amp current.
3. GENERAL REQUIREMENS

3.1 The actuators must meet the specifications / size / fit laid down in the attached
table.
3.2 The actuators shall have minimum required torque (or thrust required at the valve
stem with manual/ remote operation) and maximum allowable torque to open or
close the valve keeping in view the line pressure range between 500 – 1235 psi.
3.3 The free available space where these actuators will be installed is limited, as such;
bidder to provide dimensional drawings along-with their bid and select actuators
accordingly as per attached drawings.
3.4 The successful bidder will also be responsible for installation / testing of these
actuators.
3.5 Actuator shall be of a true modular design to simplify field service,
interchangeability of the power modules and the addition of manual overrides and
accessories. The control system must have provision for future addition of line
break, ESD devices etc. All module interfaces shall include a precision machined
pilot to ensure accurate alignment.
3.6 Valve actuator shall be designed for local and remote operation. For remote
operation actuator shall be designed to use gas from the pipeline where
valve/actuator is installed. Gas supply for the actuator shall be drawn from the
pipeline through two shut-off valves one upstream and other downstream of the
valve. Gas shall be filtered and dehydrated through a condensate separator, while
drain arrangement for condensate exhaust shall be provided.
3.7 Actuator including accessories such as cutouts and switches shall be of weather
proof and explosion-proof design meeting CENELEC or equivalent standards,
IP66 and IP 67M standards / testing and the manufacturer shall warrant that
actuators supplied are in accordance with all explosion proof requirements
applicable on site.
3.8 Electrical system / devices shall be designed for operation on nominal 24 VDC
power supply and shall be approved for use in Class, I Group “D” Division 1,
explosion proof classified areas. Necessary batteries shall be included in the
supply of actuators.
3.9 Construction of actuators shall be suitable for continuous exposure to ambient
temperatures of -15DegC to +80DegC. Actuator shall exhibit excellent corrosion
resistance conformed by salt spray testing as per ASTM B 117.
3.10 All fittings and tubing shall be 316 Stainless Steel. All electric devices used shall
be of Class 1, Group D, Division 1, explosion proof classified areas.
3.11 Manufacturer shall be provided a five year materials and workmanship warranty.
3.12 Actuator shall be provided with suitable number of integral lifting lugs to
facilitate safe shipping, handling, installation and removal.
4. SCOTCH-YOKE MECHANISM

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 Actuator shall consist of a Scotch-Yoke mechanism housed in a weather-proof container,
which makes a rotation of 90 degree (±3 degrees tolerance) under the action of a double-
acting hydraulic cylinder. The scotch-yoke housing shall incorporate visual inspection
facility for lubricant inspection and be equipped with pressure relief valve to preclude any
accidental over-pressure. All moving parts shall be mounted on bronze bearings. Yoke
shall be of hardened alloy steel. Cylinder walls shall be suitably electroplated for wear and
corrosion resistance. Hydraulic cylinder piston shall have non-rolling seals with dual
wiper/wear rings. Scotch Yoke mechanism shall be designed to counter-act side loading
effects. Scotch Yoke shall feature replaceable bearings.
5. TANKS

Gas-Over-Hydraulic or Pneumatic power gas storage tanks shall be engineered,

manufactured tested and stamped in accordance with ASME–VIII DIV. 1. The tanks for
Gas-Over-Hydraulic system shall be equipped with a dipstick screwed into the system for
oil-check. The bottom of the tanks shall be equipped with flow control valves, filters and
drain arrangement.
6. MANUAL OVERRIDE

Actuator shall be provided with emergency manual override with manual hydraulic
distribution system has manual hydraulic land pump with switching valves and hand pump
safety valve.
7. ACTUATOR SUPPLY

7.1 Actuator shall be engineered and manufactured to work with Gas/air pressure
supply varying from 100-185 psi. Actuator is to operate on line supply Gas /air
supply line shall be equipped with filtration to avoid entrance of particles, which
might prevent working of pneumatic components. Power Gas must be filtered to
50 micron on entering control unit. Filtration arrangement should incorporate
replaceable filters.
7.2 Pneumatic actuators shall be equipped with Gas/air regulation and relief valve set
for operating gas pressure.
7.3 Actuator shall be provided with a connection port to be fed by means of separate
supply line coming from a bottled gas
8. VALVE POSITION INDICATOR

8.1 Actuator shall have electric limit switches, which can be adjusted along the
complete angular stroke of the valve, limit switches are to be enclosed in weather-
proof and explosion proof enclosures. The enclosures shall be equipped with
position indicator for open-close and mid-way position of the valve along the
stroke. Local mechanical position indicator shall also be provided.
8.2 Actuator control system shall consist of a double 3-way 2 position control valve
which shall be piloted by single solenoid valve for the remote control closing and
opening also facilitating local operation by means of 2 levers.
9. JUNCTION BOX

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 Junction Box housing wiring from the actuator electric components and from the remote
control panel shall be provided with local / remote selection mode. Junction box shall be
explosion proof and weather proof suitable for outdoor installation.
10. PERFORMANCE TEST CERTIFICATE

10.1 Valve 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: -
10.2 Torque at maximum torque setting (Maximum differential pressure 100 bar).
10.3 Actuator operating time.
10.4 In addition, the test certificate should record details of specification such as gear
ratios for manual and automatic drive, closing direction and wiring diagram code
number.
11. PACKING, PAINTING AND PROTECTION

11.1 Packing shall be sufficiently robust to withstand rough handling during ocean
shipment and up-country journey. All items shall have their respective
identification letters or numbers painted on body and these shall be suitably
packed to provide case of handling and storage and maximum protection during
transport and storage periods. Crates or boxes shall have a list of items contained
therein secured to the exterior by means of an enveloping piece of tin sheet nailed
to the word. A duplicate list shall also be included inside with the contents.
11.2 Protection of the equipment against corrosion / deterioration shall be given special
attention. Machined steel and iron parts shall be heavily greased / varnished as
preventive measures against rust and grease where used shall be such that it
retains its consistency, and does not melt at tropical temperatures and is acid free.
11.3 Actuator shall be supplied with suitable lubricants. The lubricant used shall be fit
for use under site conditions specified hereunder. The actuator shall be so
designed that no lubricants will escape even under improper storage conditions.
12. QUALITY OF MATERIAL

The material used in construction of the subject item shall be the best of their respective
kinds and of the nature which experience has shown to be the most suitable for the
purpose. Special consideration shall be given on galvanic electrolytic and other destructive
actions upon the subject item.
13. MANUFACTURER’S GUARANTEE

The manufacturer shall guarantee the material, design and operation of the valve actuator
covered by the purchase order, to the extent that if any defects chargeable to faulty
workmanship, design, or material are found in the actuator within a period of two years
after installation in regular service, the manufacturer shall furnish replacement of an
defective part of the parts thereof free of charge. If the actuator is found defective at the
time it is placed in service, the manufacturer shall replace it.
14. COMPLIANCE

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 The manufacturer will be responsible for complying with all the provision of this
specification. A certificate to this effect shall be furnished with the aid. Any variation
from the specification shall be specifically indicated by the bidder in their offer.
15. TRACEABILITY / IDENTIFICATION

• Valve actuator shall be suitably and permanently marked with identification /

traceability information / data which shall include the following.
• Size / Type
• Manufacturer’s name and year of manufacturing and any specific identification No. as
per their Catalogue.
• Purchase Order / Contact No.
16. NATURAL GAS ANALYIS AND SITE CONDITONS

Gas Analysis
• The valve shall be suitable for operating on Natural Gas of the following analysis.
• Methane (CH4) =
• Ethane (C2 H6) =
• Propane (C3 H8) =
• I-Butane (C4 H10) =
• N-Butane =
• I-Pentane (C5 H12)=
• N-Pentane =
• Nitrogen (N2) =
• Carbon Dioxide (Co2)=
• Oxygen (O2) =
• Total Sulphur =
• Gas Specific Gravity=
• Hydrogen Sulphide= .
• Water
Site Conditions
• The following refers to maximum conditions likely to be met along the pipeline route.
• Maximum Shade Temperature 122Deg F
• Minimum Shade Temperature 25Deg F
• Humidity @ 70Deg F 85 %
• Humidity @ 95Deg F 78 %
• Humidity @ 105Deg F 76 %
• Humidity @ 120Deg F 70 %
• Altitude varies between 400 feet and 1700 feet above sea level.
• Atmosphere – Saliniferous corrosive and dusty.
17. SPARE PARTS
Bidders shall quote for 2 years operational spares. Each quoted item shall be individually
priced.
18. DOCUMENTATION

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Actuators shall be supplied with operation and parts manual.

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