PETRONAS TECHNICAL STANDARDS

Hydraulically Operated Shutdown Valve

PTS 14.00.07
June 2014

2014 PETROLIAM NASIONAL BERHAD (PETRONAS)

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or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright
owner. PETRONAS Technical Standards are Companys internal standards and meant for authorized users only.

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FOREWORD
PETRONAS Technical Standards (PTS) has been developed based on the accumulated knowledge,
experience and best practices of the PETRONAS group supplementing National and International
standards where appropriate. The key objective of PTS is to ensure standard technical practice across
the PETRONAS group.
Compliance to PTS is compulsory for PETRONAS-operated facilities and Joint Ventures (JVs) where
PETRONAS has more than fifty percent (50%) shareholding and/or operational control, and includes
all phases of work activities.
Contractors/manufacturers/suppliers who use PTS are solely responsible in ensuring the quality of
work, goods and services meet the required design and engineering standards. In the case where
specific requirements are not covered in the PTS, it is the responsibility of the
Contractors/manufacturers/suppliers to propose other proven or internationally established
standards or practices of the same level of quality and integrity as reflected in the PTS.
In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or
completeness of the information contained in PTS. The Contractors/manufacturers/suppliers shall
ensure accuracy and completeness of the PTS used for the intended design and engineering
requirement and shall inform the Owner for any conflicting requirement with other international
codes and technical standards before start of any work.
PETRONAS is the sole copyright holder of PTS. No part of this document may be reproduced, stored
in a retrieval system or transmitted in any form or by any means (electronic, mechanical, recording
or otherwise) or be disclosed by users to any company or person whomsoever, without the prior
written consent of PETRONAS.
The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be
kept in safe custody and shall ensure its secrecy is maintained and provide satisfactory information
to PETRONAS that this requirement is met.

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ANNOUNCEMENT
Please be informed that the entire PTS inventory is currently undergoing transformation exercise
from 2013 - 2015 which includes revision to numbering system, format and content. As part of this
change, the PTS numbering system has been revised to 6-digit numbers and drawings, forms and
requisition to 7-digit numbers. All newly revised PTS will adopt this new numbering system, and
where required make reference to other PTS in its revised numbering to ensure consistency. Users
are requested to refer to PTS 00.01.01 (Index to PTS) for mapping between old and revised PTS
numbers for clarity.
For further inquiries, contact PTS administrator at
ptshelpdesk@petronas.com.my

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Table of Contents

1.0

2.0

3.0

4.0

5.0

INTRODUCTION ...................................................................................................6
1.1

SCOPE .......................................................................................................................... 6

1.2

GLOSSARY OF TERM .................................................................................................... 6

1.3

SUMMARY OF CHANGES ............................................................................................. 7

HYDRAULIC SYSTEM GENERAL DESIGN REQUIREMENTS .......................................8

2.1

GENERAL ..................................................................................................................... 8

2.2

CENTRALISED HYDRAULIC SYSTEMS ........................................................................... 9

2.3

SELF-CONTAINED HYDRAULIC UNIT ............................................................................ 9

2.4

EQUIPMENT LAYOUT ................................................................................................10

2.5

INSTALLATION ...........................................................................................................10

2.6

FIRE RESISTANCE .......................................................................................................10

COMPONENT OF HYDRAULIC SYSTEM AND ROV................................................. 12

3.1

GENERAL ...................................................................................................................12

3.2

ACTUATOR ................................................................................................................12

3.3

POWER PACK.............................................................................................................14

3.4

ACCUMULATOR.........................................................................................................17

3.5

POWER SUPPLY .........................................................................................................18

3.6

PIPING AND TUBING .................................................................................................18

3.7

SHUT-OFF VALVE .......................................................................................................19

3.8

INSTRUMENTATION ..................................................................................................20

3.9

ESD PANEL .................................................................................................................21

3.10

LOCAL OPERATING PANEL ........................................................................................21

CONTROL FUNCTION .......................................................................................... 22

4.1

FUNCTIONAL REQUIREMENT ....................................................................................22

4.2

INSTRUMENTED PROTECTIVE FUNCTION (IPF) .........................................................23

INSPECTION TESTING AND COMMISSIONING ..................................................... 24

5.1

LEAK TEST ..................................................................................................................24

5.2

ASSEMBLY TEST .........................................................................................................24

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6.0

7.0

5.3

FUNCTION TEST.........................................................................................................25

5.4

COMMISSIONING ......................................................................................................26

REQUISITION ..................................................................................................... 28
6.1

ORDERING .................................................................................................................28

6.2

DOCUMENTATION ....................................................................................................28

6.3

NAMEPLATE ..............................................................................................................31

6.4

PACKING AND SHIPPING ...........................................................................................31

BIBLIOGRAPHY................................................................................................... 32

APPENDIX: TYPICAL CENTRALISED LAYOUT OF REMOTELY OPERATED HYDRAULIC

ACTUATED SHUT-OFF VALVE ......................................................................................... 34

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1.0

INTRODUCTION
This PTS specifies minimum technical requirements and recommendations for the design,
installation, testing and commissioning of hydraulically actuated shutdown valve and its
hydraulic power pack systems. This PTS applies to both Upstream and Downstream
applications.

1.1

SCOPE
The scope covers the design and installation of Centralised Hydraulic and Self-Contained
Hydraulic Unit (SCU) for hydraulic valves that are typically Remotely Operated Valves (ROV)
for the purpose of emergency shutdown.
It is intended for hydraulically actuated remote operated shutdown valve installed in
onshore and offshore facilities.

1.2

GLOSSARY OF TERM

1.2.1

General Definition of Terms & Abbreviations

Refer to PTS Requirements, General Definition of Terms, Abbreviations & Reading Guide PTS
00.01.03 for General Definition of Terms & Abbreviations.

1.2.2

Specific Definition of Terms

No

Term

Instrumented Protective
Function

Definition
A function comprising one or more Sensors,
a Logic Solver and one or more Final
Elements whose purpose is to prevent or
mitigate hazardous situations.
An IPF is intended to achieve or maintain a safe
state for the process, in respect of a specific
hazardous event.
In IEC 61508 and IEC 61511, an IPF is referred
to as a Safety Instrumented Function (SIF).

Instrumented Protective
System

The electromechanical, electronic and/or

programmable
electronic
Logic
Solver
component of the Instrumented Protective
Function, complete with input and output
equipment.
In IEC 61508/61511, SIS is referred to as a Logic
Solver.

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1.2.3

1.3

No

Term

Definition

Self-Contained Hydraulic Unit

A compact power pack, integrally built with

actuator on top of or next to shut-off valve
Table 1: Specific Definition of Terms

Specific Abbreviations
No

Abbreviation

Description

DCS

Distributed Control System

DE

De-Energised

ESD

Emergency Shut Down

IA

Instrument Air

IPF

Instrumented Protective Function

IPS

Instrumented Protective System

MCC

Motor Control Centre

PLC

Programmable Logic Controller

ROV

Remote Operated Shut-off Valve

10

SCU

Self-Contained Hydraulic Unit

11

SIL

Safety Integrity Level

12

PFD

Probability of Failure on Demand

Table 2: Specific Abbreviations

SUMMARY OF CHANGES
This PTS 14.00.07 replaces PTS 31.36.10.30 (August, 2012).

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2.0

HYDRAULIC SYSTEM GENERAL DESIGN REQUIREMENTS

2.1

GENERAL

2.1.1

In general, hydraulically actuated remote operated valve (ROV) is to safety isolate or

evacuate a large quantity of liquid hydrocarbon in order to prevent or to contain a fire from
escalation. In process plant, ROVs are typically installed at the suction of pumps, outlet of
large columns and storage tanks, and at the suction and discharge of compressors. In the
loading and unloading systems, ROVs are installed at the loading hoses, loading arms, and
at certain part of transmission pipelines to isolate sections of the pipeline in case of loss of
containment.

2.1.2

ROVs can be installed with a Centralised Hydraulic System, as common hydraulic power
pack, supplying hydraulic power to a number of ROVs.

2.1.3

ROVs can also be installed with dedicated Self-Contained Hydraulic Unit (SCU) to provide
dedicated hydraulic power for each ROV.

2.1.4

The selection between Centralised Hydraulic System and a Self-Contained Hydraulic Unit
must be carefully made, as any common mode failure in the Centralised Hydraulic System
will result in a number of ROVs being inoperable during an emergency. The use of a
Centralised Hydraulic System shall require the appropriate risk assessments to be made and
be approved by the Technical Authority.

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2.2

CENTRALISED HYDRAULIC SYSTEMS

2.2.1

For centralised system, the hydraulic power pack shall be designed for the appropriate
number of ROVs, as justified by the risk assessment. The hydraulic piping system shall be
able to maintained full system pressure continuously to all the ROVs. This includes the backup power source and other critical components, to guarantee the ROV operability under all
conditions.

2.2.2

The layout of the centralised system shall enable easy accessibility for manual operation,
maintenance, inspection and functional testing.

2.2.3

The shut-off valve and the actuator shall be designed as an integrated common unit. Normal
operation of the ROV shall be from the control system mounted on the actuator. If access to
the control on the actuator is restricted, a local operating panel mounted on a stand nearby
shall be installed.

2.2.4

The power pack, accumulator rack, nitrogen bottle and emergency panel should be installed
in the centralised system.

2.2.5

The centralised system shall enable 3 full strokes of all the ROVs connected to the system,
simultaneously with no power.

2.2.6

The installation shall be in compliance to the hazardous area classification for which the
equipment or components are installed.

2.2.7

Typical installation layout of ROV is shown in the Appendix.

2.3

SELF-CONTAINED HYDRAULIC UNIT

2.3.1

Self-Contained Hydraulic Unit (SCU) shall be modularly constructed. This modular

construction shall consists of the following:
i.

Shut-off valve

ii.

Actuator

iii.

Power pack

iv.

Accumulator

v.

Nitrogen bottle

vi.

Instrumentation

vii.

Local operation panel

viii.

Emergency shut-off panel

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2.3.2

The volume of oil reservoir shall be designed to have the capacity of greater or equal to 1.5
times that of the volume of the entire hydraulic fluid of the unit or be able to execute 3 full
strokes of ROV, with no power, whichever requires the more volume of hydraulic fluid.

2.4

EQUIPMENT LAYOUT

2.4.1

The layout of the centralised hydraulic system shall be sufficiently separated from ROVs, the
power pack (which includes the accumulator) and the emergency shut-off panel. The power
pack and emergency shut-off panel shall be located in an area where it is easily accessible
but away from the ROV area that may be prone to fire. The centralized system should have
a good view of equipment it is controlling. The local operating panel shall be located adjacent
to or in close proximity to the ROVs.

2.4.2

There shall only be a maximum of 15 ROVs connected to the same centralized system.

2.4.3

Each hydraulic system which control a group of ROVs shall have a minimum distance of 50m
to the next centralised hydraulic system.

2.4.4

SCU shall be considered if the total number of ROVs does not justify a centralised system, or
the ROV is located far away from the rest of the ROVs in the group or if the ROV is critical
for the safe shutdown of the facilities.

2.4.5

In cases such as loading hoses and loading arm application, the decision to have only remote
operation shall be subjected to the approval of the Technical Authority.

2.5

INSTALLATION

2.5.1

The hydraulic system installation shall enable ease operation, maintenance and troubleshooting of the system during normal operation.

2.5.2

Normal process or facility operations shall not be disturbed by minor equipment fault such
as nitrogen leak or small leakage of hydraulic fluid. The integrity of the valve to remain at its
last position shall not be affected by unintentional opening and closing of the valve.

2.6

FIRE RESISTANCE

2.6.1

For the hydraulic piping systems, and the power and control cables which form part of the
shut-off valve installed in fire zone area shall be designed to be operable for a minimum of
15 minutes when subjected to fire of temperature profile as illustrated in UL-1709. The valve
and its actuator shall also be manufactured and designed to meet similar requirements and
remain operable for the duration. To achieve this requirement, the enclosure which form an
integrated part of the module should also be a fireproof box.

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2.6.2

All power and control cables for connection between the actuator and emergency shut-off
panel shall be of fireproof construction in accordance with IEC 60331-11, i.e. shall withstand
temperatures of up to 750 C for a period of 3 hours.

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3.0

COMPONENT OF HYDRAULIC SYSTEM AND ROV

3.1

GENERAL

3.1.1

In general, each hydraulic system and the remote-operated valve comprises of the following
main components:
i.

Shut-off valve (can be designed as normally opened or normally closed)

ii.

Hydraulically operated actuator

iii.

Power pack to supply hydraulic pressure to the actuator

iv.

Accumulator to store the hydraulic pressure

v.

Pumps to pressurize the system

vi.

Back-up system to maintain the hydraulic pressure (normally pressurized

nitrogen cylinder)

vii.

Instrumentation switches and gauges

viii.

Hydraulic fluid filtration unit

ix.

Hydraulic oil reservoir

x.

Emergency shut-off panel

xi.

Mobile pump unit or hand pump

xii.

Hydraulic system piping and tubing

xiii.

Power and signal cables

xiv.

Actuator enclosure

xv.

Hydraulic system cabinet and shelter

3.2

ACTUATOR

3.2.1

General
The actuator shall be hydraulically operated double-acting cylinders or spring loaded
hydraulic cylinder. To prevent valve slamming, hydraulic damping shall be design if
necessary. The actuator movement shall be linear or rotary and directly mounted on the
valve. Piston rod assembly of the actuator shall be made of stainless steel AISI 316.
It is expected that during normal operation, there are some pressure losses in the system.
Thus, the actuator torque may need to be oversized to meet the required torque by the
valve for its closing and opening operations.
The flow rates o f t h e h y d r a u l i c f l u i d i n t h e s y s t e m are determined with the
opening/closing time of the valve.

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In case of loss of hydraulic pressure, the actuator shall hold its position through a dual overcentre valve.
The design and installation of the fire box shall have provision for connection of mobile
pump with block valves to isolate the hydraulic cylinder. It shall be possible to adjust the
valve stem position in relation to its actuator piston position. Mechanical position indicator,
proximity switches, static load thermal relief valve and vent valves shall also be part of the
design.

3.2.2

Piston Seals
Arrangement of the piston and piston rod sealing shall be such that functionality of the
hydraulic system is not affected by a single seal failure. The piston seal shall be of fire proof
design with two layer of seals. The primary seal is made of elastomeric seal and the
secondary seal is made of metal seal which is resistant to damage due to fire. In a skid which
is already made fireproof, the secondary seal may not be required.
The metal seal shall be design in such a way it will not damage the cylinder because of its
movement. The maximum leakage rate shall be as per specified under testing requirement.
Fire proof enclosure may be considered if the actuator design cannot meet the fire rating
requirement.

3.2.3

Torque
Torques required to operate the valve shall be specified by the valve manufacturer. The
torque shall be based on the specified maximum process differential pressure across the
valve in the closed position.
Even at the minimum specified hydraulic system pressure, the actuator torque shall be able
to deliver the minimum required torque to fully stroke the valve on-line, as specified in the
valve manufacturer data sheet. The delivered torque shall be adjusted accordingly if fouling
is expected.
The maximum torque load on the valve stem shall be communicated by the hydraulic
system manufacturer to the valve manufacturer, and valve manufacturer shall specify the
safety factors for torque data. At maximum system pressure, the actuator shall deliver the
torque which is less than the maximum allowable stem load specified by valve
manufacturer.
The torque values mentioned above, selected actuator type/size, and results of the actuator
sizing calculations shall be approved by the actuator system designer.

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3.2.4

Mechanical Stopper
A mechanical stopper in a form of locking device shall be installed on the actuator to block
the valve in safe position when online maintenance or testing of valve is to be carried out.
The stopper position shall be in the range of 20% to 100% closing of the valve. It shall be
designed to withstand the maximum closing torque of the actuator.
The installation of the stopper shall be such that it is clearly visible and any accidental
actuation of the valve from its safe position is not possible.

3.3

POWER PACK

3.3.1

General
The main component of power pack shall consist of motor, hydraulic pump, hydraulic
reservoir or tank, series of hydraulic filters and valves, which are assembled in a cabinet or
mounted on a skid. It shall also include instrumentation such as level gauges, level switches,
pressure gauges, pressure switches, temperature gauges and alarms, and transmitters.
The power pack shall be sized according to the number of actuator connected to the system
and for at least 3 strokes of valve operation (e.g. close, open, and close).

3.3.2

Hydraulic Filtration System

The hydraulic fluid filtration system shall consist of the following:

i.

Suction Filter installed at the pump suction, at least 30 mm above the bottom
of the reservoir or drain point. The filter shall have a nominal size of 130 m,
and the pressure drop across the filter shall not exceed 0.1 bar at the specified
viscosity and temperature range of the hydraulic fluid.

ii.

Discharge Filter installed at the pump discharge. The filter shall have a nominal
size of 10 m, and the pressure drop across the filter shall not exceed 5 bar at
the specified viscosity and temperature range of the hydraulic fluid.

iii.

Return Filter installed on the hydraulic fluid return line. The filter shall have a
nominal size of 10 m (10 100). The total perforation are of the filter shall
be at least twice the cross sectional area of the return line. The pressure drop
across the filter shall not exceed 3 bar at the specified viscosity and temperature
range of the hydraulic fluid.

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3.3.3

iv.

Filling filter - installed at the filling point of the tank. The filter shall have a
nominal size of 10 m (10 100). Manufacturer shall proposed the hydraulic
fluid filling method.

v.

Aeration Filter installed at the aeration point of the hydraulic fluid reservoir.
The filter shall include water vapour block and have a nominal size of 10 m.
The pressure drop across the filter shall not exceed 0.1 bar at the specified
viscosity and temperature range of the hydraulic fluid.

Reservoir
The material of hydraulic fluid tank or reservoir shall be made of austenitic stainless steel.
Carbon steel may be accepted provided it is coated internally and externally with corrosion
protection in accordance with PTS 15.20.03.
The reservoir shall be designed to have the capacity of hydraulic fluid for all the actuators
connected to the system including the piping/tubing and actuator cylinders. The maximum
and minimum level of the reservoir is taken as the volume displaced by the pump in 5
minutes. The full capacity of the reservoir shall be such that when it is at the maximum
level, it still be able to accommodate the hydraulic fluid drained from the piping system
and the actuator cylinders.
The reservoir shall be equipped with the following:
i.

two pumps (one duty, one standby)

ii.

separate suction and discharge filters for both pumps

iii.

one common return filter with fouling indication

iv.

an aeration filter

v.

a filling filter

vi.

a drain valve (including blind flanges),

vii.

instrumentation devices

viii.

an inspection hole with cover

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3.3.4

Hydraulic Pump

3.3.5

Pumps for the hydraulic power pack shall be electrically driven or pneumatic. Electric motor
shall be preferred as the driver for the pumps. Pneumatic driven pump shall only be
accepted where there is no possibility of hydraulic fluid carry over into the instrument air
supply line, such as having a separate air piston and hydraulic piston cylinder housings.

3.3.6

One standby and one duty hydraulic fluid pumps shall be installed. The pumps shall be of
the submerged gear type. Both pumps shall form as the integral part of the hydraulic fluid
reservoir and shall be able to charge the accumulator from empty to full condition in 120
seconds. Although the requirement for charging the accumulator from empty to full
condition is only being carried out during commissioning or total power lost, any deviation
on the charging duration shall be approved by Technical Authority.

3.3.7

The operating range of the hydraulic system shall normally fall between 150 bar and 200 bar
(gauge). Pumps shall be driven by air motors or electric motors. Electric motors shall comply
with PTS 13.20.01.

3.3.8

Mobile Pump Unit

Mobile hydraulic pump unit shall be provided as an emergency back-up and for maintenance
purposes. It shall be driven manually by hand or using compressed nitrogen. The unit shall
consist of its own hydraulic fluid tank, flexible hoses, pressure relief valve and the necessary
instrumentation gauges. The hoses shall have a minimum length of 5 m and have quick
coupling connection on its ends. The hose ends shall be protected with caps. Both suction
and discharge lines of the pump shall be provided with filters of 130 m and 10 m
respectively. The whole assembly of the mobile pump unit shall be mounted on a sturdy
frame with wheels for ease of transportation.

3.3.9

Hydraulic Fluid
Hydraulic fluid shall be supplied together with the system. The type shall be PETRONAS
Hydraulic EP for system operating below 100 C or equivalent hydraulic fluid approved by
Technical Authority. The hydraulic circuit shall be designed such that water ingress is
prevented and the fluid shall be maintained with water content < 50 ppm. There shall be
separate supply and return lines with no dead end to allow full flushing of the piping/tubing.
Sampling point in accordance to ISO 4021 shall be provided. Manufacturer shall recommend
the frequency of sample analysis based on hydraulic fluid supplier data base.

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3.4

ACCUMULATOR

3.4.1

The accumulator shall be designed to have the capacity for all the shut-off valves connected
to the system. This shall include the back-up compressed nitrogen supply from its cylinder.
It shall be capable to provide three full stroke of all the valves, i.e. closing stroke, opening
stroke and another closing stroke. The capacity means the accumulator is able to provide
the full three strokes from the moment the hydraulic pump is switched off until the last
stroke is completed. The volume of hydraulic fluid shall be at least the volume required for
three strokes of all connected actuators.

3.4.2

For charging of the accumulator, 3 sets of switches shall be provided. The first switch is set
for a fully charged accumulator and it shall stop the motor. The second switch is set at the
piston location corresponding to 5% of volume loss. This shall give command to start pump
A. The third switch is set at the piston location corresponding to 10% of volume loss. This
shall give command to start pump B, except for SCU where there may be only one pump.
The switch shall be of failsafe proximity type installed on top of the accumulator.

3.4.3

The back-up nitrogen supply shall be provide with pressure safety valve. Filters on the
nitrogen supply line, if applicable, shall be of 10 m and the maximum pressure drop across
the filter shall be less than 0.1 bar. Nitrogen cylinder shall comply with local regulations. In
the absence of local regulations, EN 1964 shall apply. The nitrogen gas volume shall be such
that the minimum and maximum system pressure will remain between 100 bar and 200 bar.

3.4.4

Piston type accumulator shall be used with no tie rods installed around the cylinder. The
material for accumulator assemblies shall be of steel. Accumulator vessel design shall
comply with PTS 12.20.01 or PTS 12.20.04.

3.4.5

The accumulator shall be mounted on a sturdy frame in vertical position. Construction of the
accumulator racks shall be of a welded steel frame and with a free standing design. The rack
shall be provided with roof or shields protecting the accumulators and nitrogen bottles
against direct sunshine and/or radiation from other heat sources.

3.4.6

The arrangement of the piston sealing shall be that a single seal failure can be tolerated
without consequences for the functionality of the complete hydraulic system. The seal
configuration should be a primary elastomeric seal for the hydraulic fluid, a primary
elastomeric seal for the nitrogen and a secondary metallic seal for both.

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3.5

POWER SUPPLY

3.5.1

Power to the hydraulic power pack shall be supplied from a vital electrical supply. Each
electrical motor shall be powered independently of each other. The main motor shall be
powered from normal supply and the back-up motor shall be connected to an emergency
switchboard with UPS. Field devices such as solenoid valve, shall be powered independently
either from DCS or IPS.

3.5.2

In the case of pneumatic motor, the instrument air supply shall be from a secured and
reliable source. The air flowrate and instrument air piping shall be sized accordingly such
that there will not be excessive pressure drop to the air supply to drive the motor.

3.5.3

The power supply failure should not result in loss of hydraulic pressure for ROVs and shall
not cause any movement the ROV stem.

3.5.4

Fire-resistant type cables shall be used for cabling. Other fireproof construction related
cables are also acceptable, e.g., signal cable installed in fire-resistant sealed instrument
cable ducting.

3.6

PIPING AND TUBING

3.6.1

Hydraulic system shall be supplied complete with all piping and tubing to ensure a fully
functional system.

3.6.2

The material for piping, tubing, fittings, couplings and isolating valves shall normally be
constructed from stainless steel AISI 316L. For severe condition, higher grade material shall
be specify by the Technical Authority. All piping material and accessories shall be
constructed in accordance with piping class X3021, as defined in PTS 12.31.02. The material
shall be certified in accordance with ISO 10474 types 3.1.B or EN 10204 types 3.1

3.6.3

For materials other than AISI 316L, the appropriate piping class shall be selected. Stainless
steel piping shall not be located directly below galvanised structures, unless proper shielding
is provided.

3.6.4

As much as practicably possible, the piping and tubing shall be shop assembled to minimise
field assembly. Pipe connections shall be butt-welded, with sufficient flanged connections
to allow flushing. Piping design, manufacturing and inspection shall be in accordance with
ASME B31.3.

3.6.5

All piping/tubing shall be adequately anchored and supported. There shall be no piping /
tubing connected or supported in a rigid and stress condition. Piping support shall be in
accordance with PTS 12.30.04. The piping shall be routed away from the area which is likely
to be exposed to fire such as near hydrocarbon pumps. Any piping installed in Zone 1 area
shall be enclosed in stainless steel sheet ducting. All piping shall not be insulated and shall
be painted in accordance with PTS 15.20.03.

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3.6.6

For pneumatic operation and/or pneumatic emergency switches, the instrument air signal
lines shall be seamless tubing of the same material as the hydraulic piping/tubing. The tubing
shall have a minimum OD of 12 mm. Electrically insulating spacer material shall be applied
between the stainless steel tubing and the metal supports, including around the fastening
U-bolt.

3.6.7

For packaged unit piping, the whole piping assembly which includes valves, fittings filters,
etc., shall be assembled as a modular unit. As much as possible, the tubing to the nitrogen
cylinders and the accumulator shall be butt-welded. However, in the connection where
dismantling is required, flanges or compression fittings is allowed. However the connection
shall either be high pressure, parallel threaded, double ferrule compression tube fittings, or
welding neck flanges in accordance with ASME B16.5. The compression fittings shall be
installed in accordance with the manufacturer's instructions. Other threaded connections
apart from the compression tube fittings shall be approved by Technical Authority.

3.7

SHUT-OFF VALVE

3.7.1

The valve manufacturer shall be responsible for the testing and certification of the valve
complete assembly. Seat leakage test and hydrostatic test of the valve shall be done in
accordance with PTS 14.10.04. The valve manufacturer also shall provide the following data
to the hydraulic system supplier;
i.

valve opening and closing forces

ii.

torques required to operate the valve, including 30% safety factors

iii.

the travel length of the stem

3.7.2

Hydraulic system supplier shall design the mounting facility of the valve in consultation with
valve manufacturer. Hydraulic system supplier shall also provide a self-aligning coupling
between the valve body and the actuator.

3.7.3

Valve with size DN 600 and smaller shall have a closing time of one second per 25 mm of
nominal diameter. Valve larger than DN 600 shall have the maximum closing time of 30 s.
However special requirement is enforced for the shut-off valve in LPG/LNG marine loading
arms where it shall be able to close within 5 s in accordance with PTS 14.12.01.

3.7.4

In determining the final valve closing time, pressure surges caused by sudden valve closure
shall be considered where in some application, the flowrate may need to be reduced.

3.7.5

The valve operation shall be designed such that it shall be able to close by means of a switch
mounted on the emergency shut-off panel or from the control room.

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3.8

INSTRUMENTATION

3.8.1

The ROV control cabinet shall be provided with all the instrumentation for continuous
monitoring and its full intended function. This shall include ROV control card (for generation
of alarms and motor start/stop signals), gauges, switches and transmitters. The selection
and installation of electric control switches shall be in accordance with PTS 13.00.01

3.8.2

Valve limit switches shall be of the proximity type and shall be in accordance with IEC 609475-2. A minimum of 2 adjustable proximity type limit switches shall be installed on the
hydraulic actuator for purpose of testing the ESD valve. One switch shall be configured to
indicate the position of the actuator when the valve has travelled over a distance of
maximum 20 % from its total stroke. This shall be used for partial stroke test. The other limit
switch shall be configured to indicate the position of the actuator when the valve has
travelled over the full stroke (100 % closed or opened). Alternatively linear variable
differential transformer LVDT can be used and it shall provide the same functions of limit
switches mentioned above.

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3.8.3

The signal cable for the proximity switches shall be an armoured screened signal cable. For
unarmoured cable, metal flexible conduit shall be provided. Cable entry to the junction box
shall be from the bottom only. The proximity switches, sensors and their associated
equipment shall be of fire-retarding construction. Alternatively, the limit switch assembly
shall be suitably protected against fire in a sealed fire-resistant box and/or enclosed by
stainless steel sheeting.

3.9

ESD PANEL

3.9.1

The emergency shut-off panel (ESD) forms an integral part of the hydraulic actuated valve
system and is installed together with the power pack and accumulator rack. It shall be
equipped with directional valves of the shear seal type with metal-to-metal contact between
the sealing elements. Piston-type directional valves shall not be used.

3.9.2

For safety purpose the ESD only allow the ROVs to be closed, and the opening of the ROV shall
be possible only via the local operating panel. Alternatives to this mode of opening and closing
of the ROV shall be approved by the Technical Authority. The ROV hydraulic flow scheme shall
be indicated on the panel.

3.10

LOCAL OPERATING PANEL

3.10.1 Normally the operation of the ROVs shall be by controls mounted on the actuator. In case of
inaccessibility to the actuator, a local operating panel or cabinet mounted on a stand should
be installed.
3.10.2 The main parts of local operating panel which is installed adjacent or near the actuator, are
the directional valves, non-return valves and speed control.
3.10.3 The directional valves shall be a three-position (open, neutral, closed), spring-centred, shear
seal type, with metal-to-metal contact between the sealing elements. Piston type directional
valves shall not be used. Utilising two-directional valves with neutral position (spring return)
is acceptable. It shall be possible to do the mechanical locking of the directional valve in the
"closed" position.
3.10.4 As an alternative to the speed control valve installed in the supply line, restriction orifice (RO)
is also acceptable. The RO shall be calculated according to the maximum viscosity of the
hydraulic fluid.

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4.0

CONTROL FUNCTION

4.1

FUNCTIONAL REQUIREMENT

4.1.1

The ROV control shall be designed such that it will only be possible to open the valve from
local operating panel, or from the actuator itself. It shall be made accident-proof where the
operation that cause the valve to move without any demand is not possible.

4.1.2

The ROVs shall be failsafe where the remote emergency operation from control room or
emergency shut-off panel, shall always overrule local operation of the ROV or ESD valve. In
case of hydraulic system failure, the valve should stay in its current position. In case of electric
power failure to solenoid valve, the valve shall move to its safe position.

4.1.3

Power and instrument signal segregation shall be done in accordance with PTS 14.00.06.
Control and Safeguarding Function (IPF) shall be executed by DCS and IPS respectively. The
manufacturer shall submit the control and safeguarding narrative of their system.

4.1.4

The fail-safe wiring of the I/Os shall be such that under normal conditions, the contact shall
be closed. For the solenoid valve to actuate the ROVs, it shall be normally energised.

4.1.5

The signal control functions shall activate the operation of valves to a pre-determined position
and shall indicate the open or closed position of the ROVs on the emergency shut-off panel.

4.1.6

Pumps shall be controlled automatically through selection switch on the power pack in such
a way that any one of the pump can be selected as the main pump and the other one as standby.

4.1.7

For accumulator, it shall be controlled based on volume where if the volume drop below 95
%, the selected main pump shall start to re-load the accumulator. If the accumulator volume
drops below 90 %, the stand-by pump shall also start. The pump(s) shall stop when the end
position of the accumulator piston is reached.

4.1.8

Alarms shall be configured in the DCS in control room. Such typical alarms are;
i.

"common trouble alarm" of the hydraulic unit, if the system is still able to
perform its emergency function;

ii.

"common failure alarm" of the hydraulic unit, if the system is no longer

able to perform its emergency function.

iii.

The detail alarm is tabulated below:

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Description

Function

Main/stand-by pump
switch

Selection

Trouble

Failure

A:B or B:A as
appropriate

Hydraulic
accumulator piston 5
% volume loss

Start main pump

Hydraulic
accumulator piston
10 % volume loss
Accumulator piston

Start also stand-by

pump

End
position
Low/low

Hydraulic return line

pressure

Low

Hydraulic fluid level

switch

Low

Hydraulic fluid level

switch
Hydraulic fluid
temperature

Low/Low

High

Running time too

long

Expired

Nitrogen accumulator
5 % pressure loss

Action/Remarks

Stop main and

stand-by pumps
Pumps are not
running
Indication of
hydraulic fluid
system leakage
Alarm
Trip main and stand- by
pump
Trip main and stand- by
pump
Accumulator will not
be fully charged

Table 3: Alarm configuration in DCS

4.2

INSTRUMENTED PROTECTIVE FUNCTION (IPF)

4.2.1

The system shall be subjected to Instrumented Protective Functions classification, e.g.,

hydraulic fluid low/low level protection are subject to a SIL (Safety Integrity Level). The detail
of IPF classification, verification and implementation rules are specified in PTS 14.12.10.

4.2.2

If an IPF classification results in requirements which are more stringent than the typical
implementation of this PTS, then the instrumentation shall follow the IPF classification results.

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5.0

INSPECTION TESTING AND COMMISSIONING

To ensure the integrity of the whole hydraulic system, a complete test shall be performed
by the manufacturer. The main test shall include leak test, assembly test and functional
test.

5.1

LEAK TEST

5.1.1

General
The main purpose of this test is to ensure the integrity of the primary and secondary seal
arrangement of the accumulator and the actuator.
For accumulators and actuators located in non-hazardous areas or on a fireproof skid, a
general leak rate test shall be performed. This shall be a 24-hour pressure test at the
maximum allowable differential pressure and the maximum pressure drop shall be less
than 0.5 %, taking into account any temperature differences between start and finish.

5.1.2

Leak rate test of accumulator

The test shall be performed with the primary seal removed to simulate the failure of the
primary seal. The acceptance criteria is the leakage rate shall be less than 60 % of the
capacity of one pump when tested at the maximum allowable differential pressure.

5.1.3

Leak rate test of actuators

The test shall be performed with the primary seal removed before assembly to simulate
the failure of the primary seal. If the secondary seal is not metallic, manufacturer shall
propose a test arrangement to simulate a primary seal failure. The acceptance criteria is the
leakage rate shall be less than 500 cm3 hydraulic fluid per minute at the maximum
allowable differential pressure across the piston. For large pistons, the leakage rate shall be
less than 1000 cm3 hydraulic fluid per minute.

5.2

ASSEMBLY TEST

5.2.1

The assembly test shall be divided into the following:

i.

Hydraulic functional tests which include the test for pump capacity, accumulator
size, operating times. This is perform at system manufacturers works which
includes power pack with actuators, including the shut-off valve. However, if a
centralised hydraulic system is used, it may not be possible to test the complete
assembly with the shut-off valve. In such cases, the centralised system shall be
separately tested from the shut-off valve.

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ii.

Valve actuator tests (hydrostatic, cryogenic etc.) at the valve Manufacturers

works, operated by a hydraulic (hand pump) unit, but without power pack;

iii.

Minimum pressure to test that the available minimum pressure by power pack is
greater than the minimum hydraulic pressure necessary to unseat the valve at
design process pressure.

5.2.2

The shut-off valve and actuator assembly shall be tested as one unit, complete with operating
controls and including the mobile pump set. Proper adjustments and settings shall be the
responsibility of the hydraulic system manufacturer. Manufacturer shall submit a functional
testing procedure for approval.

5.3

FUNCTION TEST

5.3.1

Pump capacity test

This test is carried out to confirm the pump can charge the accumulator as per the required
time. Pressurised nitrogen is used to simulate the expected pressure in the system at the
maximum ambient temperature at site.
The acceptance criteria is the accumulator can be fully charged from empty condition in 120
s or less by each single pump. When two pumps are used to charge the accumulator, the time
taken shall not be more than 60s.

5.3.2

Accumulator minimum pressure test

This test is carried out to confirm the accumulator shall be discharged from its full condition
to the empty condition within the required time. Pressurised nitrogen is used to simulate
the expected pressure in the system at the maximum ambient temperature at site.
The acceptance criteria is that the accumulator can be discharged within a time span equal
to or less than expected at site for the operation of emergency closure, manual open and
emergency closure again. The minimum hydraulic and nitrogen pressure shall be greater
than the pressure used as basis for the sizing of the actuators.

5.3.3

Accumulator capacity test

The test is done with the accumulator fully charged and the pump is switched off. The
acceptance criteria is the accumulator shall have sufficient pressure to operate all shut-off
valves for three strokes.

5.3.4

Actuator production tests

This test is carried out to confirm the correct operation of the actuator movement from local
and remote control. It is also to confirm the setting of limit switches and valve position

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indicator. The acceptance criteria is the actuator movement shall be smooth and correctly
indicated by the switches and position indicator.
For fail-close actuators, the break-open torque shall be measured at the minimum and
maximum specified hydraulic pressure.
5.3.5

Shut-off valve opening and actuator size test

This test is carried out to verify the valve can be opened smoothly under maximum
differential pressure in the line. The valve shall be opened slowly using hand pump unit. . The
acceptance criteria is the hydraulic pressure required to open the valve shall be less than the
pressure calculated for the actuator size and the required torque according to the valve
manufacturer.

5.3.6

Other functional tests are as follows:

i.

Shut-off valve operations from the local operating panel

ii.

Shut-off valve operations from the emergency shut-off panel

iii.

Leakage testing of the power pack, local operating panels, actuators and
mobile pump

iv.

A test to demonstrate the ability for operational testing to be performed

v.

Functioning of the alarm and IPS.

5.4

COMMISSIONING

5.4.1

The hydraulic pipelines shall be continuously pressurised at low (return line) pressure to
prevent air locks and to indicate possible system leakage.

5.4.2

Proper flushing need to be carried out before commissioning, in particular the interconnecting
piping. The system shall be flushed and tested in accordance with the specifications,
procedures and instructions of the hydraulic system manufacturer. This flushing/testing
procedures shall be subject to approval by owner.

5.4.3

As minimum the flushing procedure shall address the following requirements:

i.

flushing oil shall be of the same type as the hydraulic fluid required to operatethe
system;

ii.

the interconnecting piping shall be disconnected from the modules to ensure that
hydraulic components are not flushed;

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iii.

a separate flushing unit shall be used to provide an oil flow speed of at least 8
m/s;

iv.

flushing shall take place continuously in one direction until the hydraulic fluid
meets the cleanliness requirements of ISO 4406, code 15/12;

v.

filling and flushing of the hydraulic system should be done in the same direction;

vi.

after flushing, the hydraulic fluid shall be sampled from the end of the flushing
loop to check on cleanliness;

vii.

hydraulic fluid used for flushing may be returned to the system, provided
the cleanliness requirements of ISO 4406, code 15/12 are met;

viii.

before the modules are connected, the cleanliness of the accumulators shall be
checked;

ix.

after flushing, the interconnecting piping shall be pressure tested at 1.5 times the
maximum working pressure and inspected for leakage.

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6.0

REQUISITION

6.1

ORDERING

6.1.1

The requisition shall clearly define the specification of the ROVs, its functions, requirements,
and types of shut off valves to be installed, the responsibility between valve manufacturer and
hydraulic system supplier.

6.1.2

The performance of the valve and assembly shall be the responsibility of the valve
manufacturer. Manufacturer shall conduct the sizing of the actuator and provide data to the
hydraulic system supplier.

6.1.3

The engineering, delivery and functioning of the entire hydraulic system, including assembling
of ROVs or integrating third party/sub-supplier ROVs into its systems shall be under the
responsibility of the hydraulic system supplier. The supplier also shall be responsible for
supervision of ROV installation.

6.2

DOCUMENTATION

6.2.1

The hydraulic system supplier shall provide the hydraulic flow scheme and the following
engineering data and calculation of the equipment supplied;
i.

specification of the pump capacity, accumulator capacity, reservoir capacity,

heating and/or cooling requirements;

ii.

minimum system pressure to close and open all shut-off valves;

iii.

minimum required hydraulic fluid/nitrogen volume;

iv.

maximum system pressure;

v.

normal operating pressure;

vi.

return line pressure;

vii.

weights and outline dimensions of the modules;

viii.

main dimensions of the power pack with oil reservoir and of the mobile unit;

ix.

completed noise limitation sheet;

x.

required spare parts for commissioning;

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6.2.2

6.2.3

xi.

spare parts required for day-to-day maintenance for a period of three years after
commissioning via Spare Part and Interchangeability Record form (SPIR);

xii.

special tools required and recommended special tools;

The hydraulic system supplier shall compile a hydraulic data book that shall include the
following;
i.

material and test certificates as specified in the requisition;

ii.

certificates of all pressure/leakage tests, complete with process valve tag

numbers, drawing numbers, opening and closing times, valve leakage rates;

iii.

Functional Acceptance Test data: hydraulic pressures, operating forces and/or

torque requirements for both actuator and each ROV type and size;

iv.

actuator cycle test report;

v.

dimensional checks;

vi.

general arrangement and detailed dimensional drawings;

vii.

schematic drawing;

viii.

hydraulic sizing datasheets;

ix.

bill of materials;

x.

assembly and disassembly procedures;

xi.

electrical certificates;

xii.

certificate of conformance/compliance (design, assembly and testing).

xiii.

maintenance instructions for all filter

Operation and Maintenance manual to be provided by the supplier shall include as minimum;
i.

normal and emergency operation;

ii.

daily and periodic maintenance;

iii.

hydraulic flow scheme "as built";

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6.2.4

iv.

data with respect to the pressures (minimum, operating, maximum);

v.

return line pressure;

vi.

data with respect to the maximum pressure drop across each filter;

vii.

test reports;

viii.

detailed information/drawings of the components;

ix.

special tools;

x.

troubleshooting schemes;

xi.

requirements for the maintenance of hydraulic fluid cleanliness;

xii.

operational testing procedure.

xiii.

Spare Part and Interchangeability Record (SPIR)

The engineering data and calculation to be provided by the supplier shall include;
i.

Valve: Data regarding the design of the valve. These data form the basis for the
determining of the actuator.

ii.

Actuator: Selection of the actuator type (rotary or linear) and of all actuator
characteristics (swept volume, over-dimensioning, etc.)

iii.

Piping: Determining minimum pipe size, which important when the power
pack is installed remotely from the actuators.

iv.

General: Total values of all actuators together, for the sizing of the power pack.

v.

Accumulator System: Determining of the size of the accumulator and the required
volume of nitrogen to ensure good operation of the system under all
environmental conditions. The pressure alarm switches settings are also
determined in this section.

vi.

Pump Unit: Selection of the size of the pump and the p n e u m a t i c or electromotor. Also a rough indication of the tank volume is calculated.

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6.3

NAMEPLATE

6.3.1

All instruments which form part of the hydraulic system shall be provided with a stainless steel
nameplate in accordance with PTS 14.10.02. Instrument components that are packed
separately shall be identified by a stainless steel tag which properly indicates the type or
instrument number.

6.3.2

ROV Tag Number shall be clearly marked on the valves, and the visibility of the ROV number
shall not be obscured by the installation of the actuator.

6.4

PACKING AND SHIPPING

6.4.1

After Factory Acceptance Test is completed, the system shall be disassembled and all hydraulic
fluid shall be drained. Any unpainted parts shall be protected with one coat of a suitable
corrosion inhibitor and shall be adequately preserved for 6 months storage in accordance
with PTS 15.44.01

6.4.2

The system shall be disassembled in such a way that when required to re-assemble at site,
only limited interconnecting piping, electrical and instrumentation connections installations
are required. As such, the system shall be packed and shipped in modules, e.g., valve and
actuator, power pack, local operating panels, etc.

6.4.3

The main components such as valves and actuators shall be dispatched as a complete unit, in
vertical position. Wooden crates of appropriate sizes shall be used for the packing of the
disassembled modules. All instruments shall be properly packed to avoid water ingress during
transportation. Any components with opening parts such as valves and other piping shall be
covered with plastic caps. Each individual item shall be secured firmly so as there will be no
loose parts during transportation.

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7.0

BIBLIOGRAPHY
In this PTS, reference is made to the following Standards/Publications. Unless specifically
designated by date, the latest edition of each publication shall be used, together with any
supplements/revisions thereto:
PETRONAS STANDARDS
Index to PTS

PTS 00.01.01

Requirements, General Definition of Terms, Abbreviations & Reading

Guide

PTS 00.01.03

Pressure Vessels (amendments/supplements to ASME Section

VIII, Division 1 and Division 2)

PTS 12.20.01

Pressure Vessels (amendments/supplements to PD 5500)

PTS 12.20.04

Pipe Supports

PTS 12.30.04

Piping Classes Refining and Chemicals

PTS 12.31.02

Electrical Engineering Guidelines

PTS 13.00.01

Electric Machines Cage-induction Types

(amendments/supplements to IEC 60034-1 and IEC 60034-14)

PTS 13.20.01

Instrument Signal Lines

PTS 14.00.06

Instrument for Measurement and Control

PTS 14.10.02

Control Valves: Sizing, Selection and Specification

PTS 14.10.04

ESD Systems for Loading and Discharging LNG and LPG Ships

PTS 14.12.01

Classification and Implementation of Instrumented Protective

Functions

PTS 14.12.10

Protective Coatings & Lining

PTS 15.20.03

The Preservation of Old and New Equipment Piping Standing

Idle

PTS 15.44.01

AMERICAN STANDARDS
Pipe flanges and fitting NPS through NPS 24

ASME B16.5

Process Piping

ASME B31.3

Fire test of protection materials for structural steel

UL-1709

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EUROPEAN STANDARDS
Metallic products types of inspection documents
Transportable gas cylinders Specification for the design and
construction of refillable transportable seamless steel gas cylinders
of water capacities from 0.5 litres up to and including 150 litres

EN 10204
EN 1964

INTERNATIONAL STANDARDS
Hydraulic fluid power Particulate contamination analysis
Extraction of fluid samples from lines of an operating system

ISO 4021

Hydraulic fluid power Fluids Method for coding level of

contamination by solid particles

ISO 4406

Part-turn valve actuator attachment

ISO 5211

Steel and Steel Products, Inspection Documents

Tests for electrical cables under fire conditions circuit
integrity
-

ISO 10474
IEC 60331-11

Part 11, Apparatus Fire alone at a flame temperature

of at least 750 degrees Celsius

Low-voltage switchgear and control gear control circuit

devices and switching elements proximity switches

IEC 60947-5-2

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APPENDIX: TYPICAL CENTRALISED LAYOUT OF REMOTELY OPERATED HYDRAULIC ACTUATED

SHUT-OFF VALVE