NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES J.09

HYDRAULIC VALVE ACTUATORS

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

 GENERAL ENGINEERING SPECIFICATION GES J.09
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Rev 0 1999

INDEX

SEC TITLE PAGE

1.0 SCOPE OF SPECIFICATION 4

1.1 Introduction 4
1.2 Other NOC Specifications 4
1.3 Data Sheets 4

2.0 DEFINITIONS 5

2.1 Technical 5
2.2 Contractual 5

3.0 DESIGN 5

3.1 Codes and Standards 5

3.2 Basis of Selection 7
3.3 Hydraulic Actuator with Integral Electro-Hydraulic Power Units 7
3.4 Hydraulic Actuator with Remote Electro-Hydraulic Power Units 8
3.5 Hydraulic Actuator 8
3.6 Hydraulic Pump and Pump Motor 9
3.7 Motor Control System 9
3.8 Hydraulic Accumulators 10
3.9 Oil Reservoir 11
3.10 Hydraulic Tubing 11

4.0 MATERIALS 11

4.1 General Requirements 11

5.0 MANUFACTURE 12

5.1 QA/QC 12
5.2 Cleaning and Flushing Procedure 12
5.3 Identification and Labelling 12

6.0 INSTALLATION 13

7.0 INSPECTION 13

7.1 Procedures 13
7.2 Scope 14
7.3 Nameplates 14
 GENERAL ENGINEERING SPECIFICATION GES J.09
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INDEX

PAGE SEC TITLE

8.0 TESTING 14

8.1 Statutory Tests 14

8.2 Test Procedures 15
8.3 Test Certificates 15
8.4 Field Testing 16

9.0 DOCUMENTATION 16

9.1 Introduction 16
9.2 Schedules and Reports 17
9.3 Data and Calculations 17
9.4 Drawings 17
9.5 Final Records, Documents and Manuals 17

10.0 PRIOR TO SHIPMENT 18

10.1 Painting and Coatings 18

10.2 Spares 18
10.3 Packing and Storage 18
10.4 Shipping 19
10.5 Warranty 19

DATA SHEETS (3)

 GENERAL ENGINEERING SPECIFICATION GES J.09
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1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 This specification covers the minimum requirements for the design, specification, material selection,
installation, inspection, testing, documentation and preparation for shipment of hydraulic valve actuators
with integral or remote power units.

1.1.2 For shutdown and blowdown valve actuators, the requirements of the GES J.32 override the requirements
of this specification.

1.1.3 The specification does not cover the requirements of wellhead actuators for surface, sub-surface or
underwater safety valves.

1.1.4 This specification applies to equipment for refineries, onshore oil and gas installations and processing
facilities, including items purchased either directly or as a part of a package.

1.1.5 The Vendor/Contractor shall comply fully with the provisions laid down in this specification. Any
exception must be authorised in writing by the Owner. The Vendor/Contractor shall be responsible for the
complete design of the actuator/valve combination.

1.1.6 In the event of any conflict between this specification and the Data Sheets, or with any of the applicable
codes and standards, the Vendor/Contractor shall inform the Owner in writing and receive written
clarification before proceeding with the work.

1.1.7 This General Engineering Specification and the attached Data Sheets will form part of the Purchase
Order/Contract.

1.2 Other NOC Specifications

The following specifications are an integral part of this specification and any exceptions shall be approved
in advance by the Owner.

GES A.06 Site Data

GES C.55 Field Installation, Calibration and Testing of Instruments

GES J.06 Control Valves

GES J.13 Field Panels and Junction Bones

GES J.32 Emergency Shutdown and Blowdown Valves

GES L.35 Electrical Equipment in Hazardous Areas

GES X.06 Factory Coatings for Electrical Equipment and Instruments

1.3 Data Sheets

The technical data supplied by the Owner for the equipment is given on the Data Sheets which are attached
at the end of this specification. The Vendor/Contractor shall complete the Data Sheets with the remaining
information.

2.0 DEFINITIONS

2.1 Technical
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The technical terms used in this specification are defined as follows:

Opening and Closing Time

Shall mean the time measured from the initiation of the solenoid valve to actuate the valve to the point
where the valve is fully closed or fully open. The means for recording this time shall be electronic in
nature, with an accuracy of ± 2% and a hard copy of travel against time shall be provided.

2.2 Contractual

The commercial terms used in this specification are defined as follows:

Owner

The oil and gas company, an associate or subsidiary, who is the end user of the equipment and facilities.

Vendor

The company supplying the equipment and material.

Contractor

The main contractor for a defined piece of work.

Sub-contractor

A company awarded a contract by a Contractor to do part of the work awarded to the Contractor.

Inspection Authority

The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and
facilities have been designed, constructed, inspected and tested in accordance with the requirements of this
specification and the Purchase Order/Contract.

Inspector

A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection Authority,
who verifies that the equipment and facilities have been designed, constructed, inspected and tested in
accordance with the requirements of this specification and the Purchase Order/Contract.

3.0 DESIGN

3.1 Codes and Standards

The hydraulic valve actuator design shall comply with this specification and the following codes and
standards.

Unless otherwise specified in the Purchase Order/Contract, the current editions of the codes and standards
at the time of the order shall be used.

American National Standards Institute (ANSI)

ANSI/UL 1203 Explosion-proof and Dust-ignition-proof Electrical Equipment for use

in Hazardous (Classified) Locations
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American Society of Mechanical Engineers (ASME)

ASME B1.20.1. Pipe Threads, General Purpose (inch)

ASME B16.5 Pipe Flanges and Flanged Fittings

ASME B16.34 Valves-Flanged, Threaded and Welding End

British Standards Institution (BSI)

BS 5045 (Part 1) Transportable Gas Containers - Specification for Seamless Steel Gas Containers
above 0.5 litre water capacity

BS 5500 Specification for Unfired Fusion Welded Pressure Vessels

International Electro Technical Committee (IEC)

IEC 6079: Parts 1-15 Electrical Apparatus for Explosive Atmospheres

IEC 85 Method for Determining the Thermal Classification of Electrical

Insulation

IEC 60529 Classification of Degrees of Protection Provided by Enclosures

Instrument Society of America (ISA)

ISA-RP 12.1 Definitions and Information Pertaining to Electrical Instruments in

Hazardous Atmospheres

ISA RP 12.6 Wiring practices for Hazardous (Classified) locations Instrumentation -

Part 1: Intrinsic Safety

National Fire Protection Association (NFPA)

NFPA-70 National Electrical Code (NEC), Article 500

National Electrical Manufactures Association (NEMA)

NEMA 250 Enclosures for Electrical Equipment (1000 volts maximum).

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3.2 Basis of Selection

3.2.1 Electro hydraulic actuators are normally costly, complex and difficult to maintain and should be avoided if
possible.

3.2.2 Hydraulic actuators with integral electro-hydraulic power units may be used for the following non safety,
process control related duties:

- with modulating control valves where no instrument air is available;

- with on/off valves where the speed of opening and closing the valve is not critical.

3.2.3 Hydraulic actuators with remote electro-hydraulic power units may be used for the following safety and
process control duties and where other requirements cannot be met using pneumatic or electric motor
operated actuators:

- with quarter turn shutdown or blowdown valves where actuator torque cannot be provided by
pneumatic operators;

- high speed of operation and accuracy of positioning is required, e.g. turbine fuel control;

- good fire resistance is required. Fire protection can be conveniently and economically provided with
hydraulic actuators (relative to pneumatic or electric motor operated actuators);

- good reliability is required (provided it is regularly maintained).

3.2.4 Specialised valves utilising servo amplifiers controlled operators (e.g. catalytic cracker slide plate valves)
shall preferably be supplied with integral dedicated hydraulic power units.

3.3 Hydraulic Actuator with Integral Electro-Hydraulic Power Units.

3.3.1 The actuator shall consist of a hydraulic actuator (complete with limit switches and/or valve position
indicator) and an electro-hydraulic power source assembled as an integral unit with no external piping or
oil reservoir.

3.3.2 The unit shall be suitable for operation in accordance with the hazardous area classification stated on the
Data Sheets.

3.3.3 Manual operation shall be provided by means of a hydraulic handpump assembly. A manual selector switch
shall be set for open or close operation independent of the motor.

3.3.4 The hydraulic power operation shall override the hand operation irrespective of the selector switch
position.

3.3.5 Integral power units shall include an auto/manual switch and push buttons for the selection of "CLOSE",
"OPEN" or "STOP" functions. The manual/auto switch shall be suitable for padlocking in the "AUTO"
position.

3.3.6 Hydraulic actuator, pump and motor requirements shall be as per Sections 3.5 and 3.6 of this specification.

3.3.7 The motor control enclosure shall contain mechanically and electrically interlocked contactor(s) each
including three auxiliary contacts (two normally open and one normally closed)

3.3.8 The motor control enclosures shall contain either analogue current input facility or relays and interposing
relays for the remote operation of the system, and remote lamp indication.
3.4 Hydraulic Actuator with Remote Electro-Hydraulic Power Units
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3.4.1 A remote high integrity hydraulic power source, common to one or more actuators may be utilised where
economically justified.

3.4.2 The system will normally include the following components:

- hydraulic actuator;
- hydraulic pump and pump motor;
- control system;
- hydraulic accumulators;
- oil reservoirs;
- hydraulic tubing.

3.5 Hydraulic Actuator

3.5.1 The basic actuator shall consist of a Hydraulic Operator and an integral position/limit switch compartment.
Exposed torque arm type of operator is not allowed.

3.5.2 The hydraulic operator shall meet the required torque or thrust conditions at a hydraulic supply pressure of
1500 psi (10 MPa).

3.5.3 The operator shall be suitable for continuous operation at a pressure of 3000 psi (20 MPa).

3.5.4 Manual operation shall be provided by means of a hydraulic handpump assembly. The torque to operate
the hand pump shall not exceed 258 ft lb (350 Nm). A manual selector switch shall be set for open or close
operation independent of the motor.

3.5.5 The hydraulic power operation shall override the hand operation irrespective of the selector switch
position.

3.5.6 The handpump drive shall automatically disengage when remote control is operated.

3.5.7 Valve shaft loads shall be absorbed by the casing of the actuator (side loads in the case of quarter turn
actuators).

3.5.8 For rising stem valve actuators only, a hydraulic or mechanical lock shall be provided which will hold the
valve in the last or alternatively in the open position in the event of loss of system hydraulic pressure. The
lock shall release from the latched position on reapplication of hydraulic pressure or by operation of a
remote "trip signal".

3.5.9 The actuator shall include a valve position indicator, made from stainless steel, which shall be visible from
30 ft (10 m).

3.5.10 A dust tight removable valve stem protector shall be provided.

3.5.11 For quarter turn valves, the stops shall be adjustable ± 5 degrees at each end of the valve stroke.

3.5.12 Positive mechanical stops, capable of absorbing thrust or torque in excess of that required to operate the
valve shall be provided for gate valves. The stops shall be externally adjustable.

3.5.13 The integral limit/position switches shall be mechanically actuated by the actuator stem and be double pole,
single throw, environmentally sealed, snap acting with wiping contacts.

3.5.14 The switches shall be mechanically adjustable over the full range of travel.

3.5.15 Additional limit switches shall be provided to detect the fully open and closed positions for remote
indication. These shall be single pole changeover type, hermetically sealed, hard gold plated, snap acting
with wiping contacts. Limit switch rating shall be as stated on the Data Sheets(s).
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3.5.16 When two speed valve operation is specified, additional switches shall be used to specify the slow speed
portion of the valve travel.

3.5.17 Where specified a potentiometer or differential linear transformer shall be included to give a remote
continuous indication of valve position. Potentiometers shall be three wire, rated at minimum of 3 watts and
be suitable for continuous operation at the specified voltage against the specified resistance value. Linear
transformers shall be suitable for operation with an energising supply of nominally 5V r.m.s. at a nominal
frequency of 5 kHz. The sensitivity of the linear transformer shall be between 1 and 4V r.m.s. per inch of
actuator stroke.

3.5.18 An external lug shall be fitted to accommodate a grounding connector of 8 AWG (10 mm²).

3.6 Hydraulic Pump and Pump Motor

3.6.1 The hydraulic pumps shall be positive displacement to the Vendor/Contractor's standard specification.

3.6.2 The electric motor shall be suitable for operation in accordance with the Area Classification.

3.6.3 The electric motor shall be a 3 phase, low inertia, squirrel cage, non fan cooled type.

3.6.4 The motor windings shall be suitable for "direct on line" starting for intermittent service at the specified
voltage.

3.6.5 The motor shall be factory sealed unit of `O' ring or gasket sealed construction. Otherwise the motor
enclosure shall include vent and a drain.

3.6.6 The motor shall be protected against windings burn-out due to stall or overload. The protection shall be
either by self-resetting thermal protection based on embedded winding temperature detectors, or by means
of a "quick trip" current sensing overload relay in all three phases. Thermal protection shall be independent
of the ambient temperature variations. The operation of the protective devices shall be available on
terminals for external indication.

3.6.7 The motor shall be designed for a temperature of not less than 36°F (20°C) below that allowed in the
national or international codes or standard for the class of insulation used. Unless otherwise stated, Class
"F" insulation with a Class "B" temperature rise in accordance with BS 2757 shall be utilised.

3.6.8 Motor rated duty voltage and frequency shall be as stated on the attached Data Sheets.

3.6.9 Motor shall operate successfully at rated load and at rated frequency with a voltage variation of 10% above
or below rated voltage, and with a supply characteristic of not more than 5% total harmonic distortion
(THD). Motor shall operate successful at rated load at rated voltage with a frequency variation of 5%
above or below rated frequency.

3.6.10 Where the design includes for the continuous running of the motor and pump, low pressure pump
unloading devices shall be included to restrict the oil reservoir temperature increase to 45°F (25°C).

3.7 Motor Control System

3.7.1 The motor control system enclosure shall be suitable for operation in accordance with the Area
Classification.
3.7.2 The electrical enclosure shall be fitted with a breather and drain unless totally "O"-ring or gasket sealed.

3.7.3 The motor control system enclosure shall contain mechanically and electrically interlocked contactor(s)
each including three auxiliary contacts (two normally open and one normally closed).

3.7.4 The motor control system enclosures for all valves except emergency shutdown or blowdown valves shall
 GENERAL ENGINEERING SPECIFICATION GES J.09
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contain relays and interposing relays for the remote operation of the system, and remote lamp indication.

3.7.5 Vent and drain connections shall be provided at physically high and low points.

3.7.6 Where the design includes for the continuous running of the motor and pump, low pressure pump
unloading devices shall be included to restrict the oil reservoir temperature increase to 45°F (25°C).

3.7.7 Each actuator shall be capable of local operation either by means of solenoid or direct operation of the
hydraulic valves, as specified.

3.7.8 Manual operation shall be provided by means of a portable hydraulic handpump assembly for all valves
except emergency shutdown or blowdown valves. A manual selector switch shall be set for open or close
operation independent of the motor.

3.7.9 Where actuators remain stationary for prolonged periods (e.g. ESD systems), or incorporate hydraulic lock-
up features, poppet valves shall be used in preference to spool valves.

3.7.10 Check valves shall be fitted where necessary to prevent cross feeding of circuits. However, detailed design
shall be such that free flow of fluid to and from the actuator in an emergency shutdown situation is not
prevented.

3.7.11 Thermal relief valves shall be provided where any part of the system may become locked-in.

3.7.12 Design shall prevent return line foaming phenomena i.e. return line shall be below the minimum liquid
level.

3.7.13 An external lug shall be fitted to accommodate a grounding connector of 8 AWG (10 mm²).

3.8 Hydraulic Accumulators

3.8.1 The accumulator bank volume shall be sized for stipulated number of valve strokes under maximum
process operating conditions and minimum supply pressures. Means shall be provided for replacing one
accumulator for checking the charge of an accumulator without affecting the operability of the valve. Each
accumulator shall have independent block and bleed valves for testing/maintenance.

3.8.2 It shall be possible to charge the accumulator with the power pack and then cycle each system twice
without the pumps.

3.8.3 Accumulators shall be of the nitrogen pre-charged bag or piston type.

3.8.4 Accumulators shall be constructed to BS 5045 Part 1, BS 5500 or to an equivalent international standard
subject to the Owner's approval.

3.8.5 The accumulators shall have a relief valve to API 526, mounted on top on the gas side. Relief valve
accumulation shall be 10%. Valve shall reseat fully following operation.

3.8.7 A poppet valve shall be fitted on the oil side to prevent the bladder being extruded out of the shell.

3.9 Oil Reservoir

3.9.1 The reservoir for a system not incorporating accumulators shall be sized to be not less than 10% full of oil
with the system charged and not more than 90% full of oil with system discharged.

3.9.2 The reservoir for systems with actuators shall be sized to be approx 50% full with the accumulators charged
and not more than 90% full with the accumulators discharged.

3.9.3 The reservoir shall include mechanically tight covers, breathers, magnetic swarf collectors and a sight glass
 GENERAL ENGINEERING SPECIFICATION GES J.09
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with marks to show when the system or all accumulators are charged.

3.9.4 The reservoir shall include a filler cap attached to the reservoir by means of a chain. The standpipe shall be
of the non-overfill type.

3.9.5 The reservoir shall include a filler tube, drain line and a relief valve.

3.9.6 The reservoir shall include a low oil level switch to trip the motor.

3.9.7 A 100 micron, stainless steel, large surface area filter, shall be included in the pump oil inlet line. Dual
filters shall be incorporated on the pump discharge side.

3.9.8 A low resistance double check valve shall be included in the pump oil inlet line, pumps discharge line and
return line.

3.9.9 The hydraulic system shall be fully protected against the ingress of dirt or moisture (including absorption
by the hydraulic oil of moisture from the atmosphere), preferably by means of a nitrogen blanket. If bag
seals are used for this purpose, the system shall be sealed to maintain the minimum pressure imposed by the
bag.

3.10 Hydraulic Tubing

3.10.1 Hydraulic tubing above 0.6in (16 mm) shall be of all welded construction.

3.10.2 Tubing below this size shall use double ferruled fittings to the system Vendor/Contractor's standard. All the
fittings in a system shall be purchased from a single nominated manufacturer to avoid problems with
interchangeability.

3.10.3 Tubing and fittings shall be assembled strictly in accordance with the manufactures instructions.

3.10.4 Vent and drain connections shall be provided at physical high and low points.

3.10.5 Low resistance i.e. full bore inlet valves and short inlet pipe runs to the pump shall be utilised.

4.0 MATERIALS

4.1 General Requirements

4.1.1 Operator cylinders shall be seamless carbon steel.

4.1.2 Actuator spring shall be of carbon steel and be permanently treated to prevent corrosion. Cadmium plating
is not acceptable.

4.1.3 Actuator nuts and bolts material for pipeline shutdown valves shall be agreed between the
Vendor/Contractor and the Owner.

4.1.4 The actuator internals shall be packed for life with suitable lubricants. Repacking the actuator at site in-situ
shall be possible.

4.1.5 Tubing shall normally be of AISI type 316 SS and shall have NPT connections.

4.1.6 The reservoir and all reservoir system components shall be manufactured from SS. Alternatively, the
reservoir may be manufactured from carbon steel with an internal phenolic epoxy coating.
4.1.7 Unless otherwise stated, all system components shall be made out of 316 SS.
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5.0 MANUFACTURE

5.1 QA/QC

The Vendor/Contractor shall submit to the Owner, for approval, details of his proposed quality assurance
and Quality Control Plan.

5.2 Cleaning and Flushing Procedure

A procedure for flushing and testing for cleanliness shall be provided by the Vendor/Contractor for
approval. The hydraulic oil to be provided shall be subject to Owner's approval.

5.3 Identification and Labelling

All hydraulic valve actuators shall be provided with identification tag plates and original manufacturers
nameplates.

The actuator identification tag plate shall be SS, engraved or stamped with the valve tag number and
securely attached to the valve.

The actuator identification plate shall be separate to the manufacturer's nameplate and as a minimum shall
carry the following information.

- manufacturer's name, model and serial number;

- date of manufacturer (month/year);

- Owner's Purchase Order/Contract number;

- direction of rotation;

- rated hydraulic supply pressure;

- maximum torque output;

- type of hydraulic fluid/lubricant;

- electrical enclosure certification.

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System cabinets shall be fitted with SS screw attached white/black/white traffolyte engraved labels bearing
the valve tag number in 0.5 in (12 mm) high characters and the part identity in 0.25 in (6 mm) high
characters.

6.0 INSTALLATION

6.1 All actuators/valves shall be checked for damage and conformity to the Purchase Order/ Contract
immediately on receipt at site.

6.2 All actuator accessories for installation in hazardous areas shall be checked to ensure the suitability of the
protection for the relevant area classification.

6.3 Where a complete valve assembly has been ordered, the actuator shall be fitted to the valve at the valve
manufacturer's premises. Limit and torque switch settings shall be adjusted at this stage.

6.4 Where the actuator is supplied separately to the valve, standard yokes and couplings shall be used for the
valve attachment.

6.5 Actuator shall be mounted direct onto the valve.

6.6 The actuating system components shall preferably be mounted on the actuator valve assembly. When the
complexity of the system or accessibility for maintenance does not allow this, then the system shall be
separately housed.

6.7 The control cabinet mounting shall be such that its base and the top shall be between the limits of 32 in
(800 mm) and 66 in (1650 mm) above grade.

6.8 The actuator shall be installed such that, if possible, it is in-line with the valve.

6.9 Where necessary, additional actuator supports shall be provided.

6.10 Where the control cabinet is separate from the valve actuator, the inter-connecting hydraulic oil piping may
be erected by others (Owner or a sub-contractor). The Vendor/Contractor shall specify the line sizes to
meet the timing criteria.

7.0 INSPECTION

7.1 Procedures

7.1.1 The inspection requirements are covered by the document "General Conditions of Purchase" which forms
part of the Purchase Order/Contract. Additional requirements are given below.

7.1.2 All inspection activities to be performed including any special requirements shall be agreed with the Owner
and shall be incorporated within the agreed Quality Control Plan provided by the Vendor/Contractor.

7.1.3 The Vendor/Contractor shall allow the Inspector free access to all areas of manufacture, fabrication,
assembly and testing.

7.1.4 The Vendor/Contractor always has the responsibility to provide adequate quality control and inspection of
equipment and materials in accordance with the QA/QC procedures. Any inspection by the Owner or his
Inspector shall not relieve the Vendor/Contractor of these responsibilities or those under his warranties.

7.1.5 The Vendor/Contractor shall demonstrate to the satisfaction of the Owner that his quality plan will be such
as to ensure close agreement between the performance of random production samples and those submitted
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for certification.

7.2 Scope

7.2.1 Since the actuators will normally be delivered to the valve Vendor/Contractor's premises, the initial
inspection will be carried out by the valve Vendor/Contractor. The Vendor/Contractor may be requested to
provide details of his inspection and testing procedures and to provide the results of specific tests.

7.2.2 The following shall be checked prior to any fabrication being carried out:

welders qualification records;

welding procedure specifications;
procedure qualification records;
qualification of fire proofing (if specified).

7.2.3 The following shall be checked for compliance:

workmanship;
material quality;
surface defects of components and dimensions;
Purchase Order/Contract;
details and specifications;
certified drawings;
catalogue description;
paint specification.

7.3 Nameplates

The identification number of each actuator shall be clearly marked on a nameplate, permanently fastened
(not bonded) to the actuator, in a clearly visible position.

The original manufacturer's nameplate shall include the data specified in Section 5.3.

8.0 TESTING

8.1 Statutory Tests

8.1.1 Valves/actuators/control systems shall be subjected to the factory tests listed in this section. The Owner
may, at his discretion, witness all or part of the factory tests. The tests results shall in any case be made
available to the Owner.

8.1.2 Approval by the Owner's inspector shall not relieve the Vendor/Contractor of his commitments under the
terms of the Purchase Order/Contract and this specification.

8.1.3 Welding and NDT testing shall be in accordance with the requirements of the relevant piping specification.
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8.1.4 A final witnessed factory testing of the actuators shall take place at the valve manufacturer's premises.

Witnessed testing is required if:

- the actuator is used on a safety related application;

- the actuator is a new model;

- the actuator Vendor/Contractor is a newly qualified manufacturer;

- the actuator can not be tested at site;

- the actuators/valves have undergone major modifications to meet specific requirements.

Otherwise, the final witnessed factory testing may be waived subject to the Owner's written permission.

8.2 Test Procedures

8.2.1 The Vendor/Contractor shall submit his test procedures in writing to the Owner for approval, prior to the
start of the testing programme.

8.2.2 The pressure tests shall be carried out in the presence of Inspector(s) from the Owner's Inspection
Authority.

8.2.3 A 5 minute leak test shall be carried out at 150% of maximum operating pressure of the actuator.

8.2.4 High voltage tests shall be conducted on motor, control circuitry and interposing relays.

8.2.5 Motor current shall be recorded for starting torque, stall torque and rated torque.

8.2.6 For ON/OFF and modulating duties, the motor shall be loaded to 33% of maximum rated output torque for
15 minutes and the temperature rise limit verified.

8.2.7 The actuator shall be tested for actuator stem travel or shaft rotation, stroking speed, fail safe operation, and
the overall actuator assembly against the requirements of the equipment specification.

8.2.8 Tests shall be made at load (using torque simulator, if required) and no load and shall ensure that all
devices operate as intended, such as pressure switches, limit switches, solenoid valves, pressure relief
valves, speed control valves, hand operation and automatic override.

8.2.9 A test shall be carried out to demonstrate that the actuator does not exceed maximum valve stem torque.

8.2.10 An accumulator capacity test shall be carried out to demonstrate that the actuator can be stroked for a
stipulated number of times with the main motive power (electricity or air) isolated.

8.3 Test Certificates

In addition to the Test Reports and letters of conformity, the following certificates shall be provided with
each actuator as minimum:

- Inspection Release Certificate.

- Code Compliance Certificate.
- Type Test Certificate.
- Material Certificates.

8.4 Field Testing

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8.4.1 General

Actuator/valve functional and leak tightness testing shall be carried out in the workshop before installation.

All tests shall simulate, as far as reasonably practicable, the design process conditions.

8.4.2 Actuators with Integral Electro Hydraulic Power Unit

Integral electro-hydraulic power unit actuators shall be tested for remote and local manual operation.

8.4.3 Actuators with Remote Hydraulic Power Units

If the actuator and hydraulic power unit is Vendor/Contractor's standard in-line on/off valve type, then refer
to Section 6.10.

If the valve or actuator is of a specialised nature e.g. catalytic cracking slide plate valve, variable orifice
valve for waste heat boiler, flue gas directing valve etc., then the Vendor/Contractor may be required to
provide assistance at installation/commissioning stage.

9.0 DOCUMENTATION

9.1 Introduction

9.1.1 This section covers the documentation required for the design, fabrication, inspection and testing of the
hydraulic valve actuators.

9.1.2 The detailed list of documents that are required is attached to the Purchase Order/Contract. However, as a
minimum the following listed documents shall be provided by the Vendor/Contractor:

- general arrangement drawing and bill of material;

- the Quality Control Plan;

- material certificates;

- weld procedure;

- NDT procedures and records.

- actuating fluid consumption, both maximum value under idling or steady state conditions and peak
value during stroking;

- if nitrogen operated, document detailing minimum operating pressure and maximum allowable pressure
of the nitrogen supply defined for the power unit only;

- actuator mounting details;

- accumulator sizing calculations;

- flushing and testing for cleanliness procedure;

- total electrical consumption and input resistance of control signal receiving elements (electro-hydraulic
transducer or electro-hydraulic positioner);

- hazardous area certificates;

 GENERAL ENGINEERING SPECIFICATION GES J.09
HYDRAULIC VALVE ACTUATORS Page 17 of 19
Rev 0 1999
- hydrostatic pressure tests procedures and test certificates;

- performance test procedures and test certificates;

- non-conformity records;

- certificate of conformity;

- Owner's Release Certificate.

9.2 Schedules and Reports

The Vendor/Contractor shall submit with his tender a preliminary Quality Control Plan. The
Vendor/Contractor shall supply a schedule showing the documents for review and approval, proposed sub-
contractors and material procurement, and a production/fabrication programme.

9.3 Data and Calculations

9.3.1 The Vendor/Contractor shall submit all calculations and data for acceptance by the Owner within the period
specified by the Purchase Order/Contract. The calculations and data shall become the property of the
Owner after acceptance.

9.3.2 All calculations shall be carried out in a logical manner. Where conditions involve the use of formulae or
method not specified in the codes or standards, the source of these formulae or methods shall be clearly
referenced.

9.3.3 Computer calculations will only be acceptable if all input is shown, together with calculated values if
intermediate terms and factor and options chosen as well as final calculated values and the computer
programme has been validated to the satisfaction of the Owner.

9.3.4 Calculations and drawings or any other documents which are interdependent i.e. actuator sizing shall be
presented for appraisal together.

9.4 Drawings

The required drawings shall be sent by the Vendor/Contractor to the Owner and/or Inspection Authority for
review and approval.

9.5 Final Records, Documents and Manuals

9.5.1 Two copies of the Data Book and six copies of the Installation/Operating/Maintenance Manual shall be
supplied with the equipment.

9.5.2 The Installation, Operations and Maintenance Manual (IOM) shall be specifically compiled for the
equipment supplied. A compendium of manufacturer's data for a range of like products is not acceptable.
The IOM shall contain as a minium the following:

- a description of the equipment;

- a master document list and certified copies of control schematics and key drawings;

- packing, shipping and site preservation instructions;

- step by step installation instructions;

- step by step pre-commissioning procedures;

 GENERAL ENGINEERING SPECIFICATION GES J.09
HYDRAULIC VALVE ACTUATORS Page 18 of 19
Rev 0 1999
- step by step procedures for dismantling and re-assembly;

- normal operating and set point values of all instruments;

- routine preventative maintenance schedule of major repair procedures;

- lubrication, hydraulic fluid, consumables schedule;

- list of special tools;

- spare parts ordering information.

10.0 PRIOR TO SHIPMENT

10.1 Painting and Coatings

10.1.1 Painting of hydraulic valve actuators shall be in accordance with GES X.06.

10.1.2 Painting and protective coatings shall take into account the methods of transport to be used.

10.1.3 Vendor/Contractor's standard painting and coating systems may be acceptable subject to the Owner's
approval, provided they are equal or better to the Owner's standards specified in GES X.06 and are equally
suitable for the site environmental conditions specified in GES A.06.

10.2 Spares

The Vendor/Contractor shall submit with his proposal, a priced list of recommended spares for start-up and
two years operation.

10.3 Packing and Storage

10.3.1 This section describes the minimum requirement for the preservation and protection of hydraulic valve
actuators and accessories during sea and land transportation and storage.

10.3.2 The probable storage period will be specified in the order/enquiry and will extend from the time of
despatch to the time of unpacking at site. If the storage period is not stated, a minimum period of 24
months shall be assumed. Packing shall be suitable for sea freight.

10.3.3 All actuators shall be securely packaged and protected against external damage.

10.3.4 Machined or threaded exterior surfaces shall be protected during shipment and subsequent storage with a
rust preventative which is easily removed with a petroleum solvent.

10.3.5 Threaded end connections shall be fitted with metal, wood or plastic plugs or caps.

10.4 Shipping

The actuators shall not leave the Vendor/Contractor's works for shipment, other than for fitting to the valve,
until the release has been approved by the Owner's Inspector.

10.5 Warranty

10.5.1 The Vendor/Contractor shall warrant all materials and services under the Purchase Order/Contract against
any defect, for a minimum period of 12 months after commissioning, or 24 months from the date of
delivery to the stipulated point of delivery, whichever is the shorter period, or such period as may be
expressly stated in the Purchase Order/Contract.
 GENERAL ENGINEERING SPECIFICATION GES J.09
HYDRAULIC VALVE ACTUATORS Page 19 of 19
Rev 0 1999

10.5.2 Should any item be found defective, the Vendor/Contractor shall be responsible for all costs associated
with restoring the equipment to the standard specified in the Purchase Order/Contract.

10.5.3 The Vendor/Contractor shall undertake to carry out the repair or replacement in an expeditious manner.

10.5.4 The terms and conditions of the Warranty shall be additional to any other requirements specified in the
Purchase Order/Contract.
 DATA SHEET No.

HYDRAULIC OPERATED ACTUATOR

P.O. / CONTRACT No.
CLIENT
PLANT LOCATION SHEET 1 of 3
SERVICE ITEM No. No. of UNITS

1 VENDOR / CONTRACTOR
2
3 CLIMATIC CONDITIONS
4 Min Temperature °F (°C)
5 Max Temperature °F (°C)
6 Max Direct Solar Temperature °F (°C)
7 Relative Humidity %@ °F (°C)
8 Atmosphere
9
10 AREA CLASSIFICATION
11 Zone
12 Apparatus Gas Group
13 Temperature Class
14
15 TYPE OF PROTECTION
16 Instrumentation
17 Junction Boxes
18 Certification
19 Degree of Protection
20
21 INSTRUMENT AIR/NITOGEN/PROCESS GAS
22 Min Design Pressure psig (kPag)
23 Normal Pressure Range psig (kPag)
24 Max Design Pressure psig (kPag)
25 Dew Point °F (°C)
26 Process Gas Contaminants
27
28
29 ELECTRICAL
30 Three Phase V +/- Frequency Hz +/-
31 UPS Single Phase V +/- Frequency Hz +/-
32 Solenoid Valve Control Voltge V +/- Floating/Earthed DC
33
34
35 TO BE AGREED WITH THE OWNER
36 Tubing/Fittings Manufacturer
37 Solenoid Valve Manufacturer
38 Type of Hydraulic Fluid
39
40
41
42
43
44
45
Revision No./Date
Prepared by/Date
Authorised by/Date
Purpose
(C) 1999 NATIONAL OIL CORPORATION. The information on this sheet may be used only for the purpose for which it is supplied by NOC.
K:\nocspecs\SPECIFICATIONS\j-series\j-09\DJ0901R0.xls Sheet1
 DATA SHEET No.

HYDRAULIC OPERATED ACTUATOR

P.O. / CONTRACT No.
CLIENT
PLANT LOCATION SHEET 2 of 3
SERVICE ITEM No. No. of UNITS

1 VENDOR / CONTRACTOR
2
3 TAG NO.
4
5 Service
6 Line No./Vessel No.
7 Body Size in (mm)
8 Type of Valve
9 Bore/CV full/reduced / / / /
10 ANSI Rating
11 Seat Leakage ANSI class
12 End Connections
13
14 Breakaway Torque Reqd ft lb (Nm)
15 Running Torque Reqd ft lb (Nm)
16 Seating Torque Reqd ft lb (Nm)
17 Actual Actuator Torque ft lb (Nm)
18 Actual/ Required Torque Ratios
19
20 Process Minimum Pressure psig (kPag)
21 Process Maximum Pressure psig (kPag)
22 Process Minimum Temperature °F (°C)
23 Process Maximum Temperature °F (°C)
24 Valve Survival Temperature °F (°C)
25
26 Actuator Control Type
27 Valve Closing Speed sec
28 Valve Opening Speed sec
29 Type of Actuator
30 Number of Strokes
31 Cylinder Material C.St/St.St.
32 Servo Operation
33 Fire Proofing
34 St. St. Quick Exhaust Valve
35 Fusible Plug
36 Additional Limit Switches
37 Potentiometer/LVDT
38 Manual Operation
39
40 Valve Vendor
41 Valve Model Number
42 Actuator Vendor
43 Actuator Model number
44
45
Revision No./Date
Prepared by/Date
Authorised by/Date
Purpose
(C) 1999 NATIONAL OIL CORPORATION. The information on this sheet may be used only for the purpose for which it is supplied by NOC.
K:\nocspecs\SPECIFICATIONS\j-series\j-09\DJ0901R0.xls Sheet2
 DATA SHEET No.

HYDRAULIC OPERATED ACTUATOR

P.O. / CONTRACT No.
CLIENT
PLANT LOCATION SHEET 3 of 3
SERVICE ITEM No. No. of UNITS

1 VENDOR / CONTRACTOR
2
3 TAG NO.
4
5 MAIN POWER SOURCE
6 Electricity
7 Line Pressure psig (kPag)
8 Portable Compressor
9 Nitrogen Bottle
10 Power Pack Location
11
12 MAIN MOTOR DRIVE DETAIL
13 Motor Duty Rating kW
14 Min Insulation Class
15 Speed Control Single/2 Speed
16 Application Part Turn/Linear
17
18 OTHER
19
20 Handwheel Yes/No
21 Anti Condensation Heater Yes/No
22 Fail Safe Actuation via Battery/Pneu/Spring
23
24 CONTROL OPTIONS
25 Pressure Pilots
26 Local Control Pushbutton
27 Selector Switch
28 Remote Control Signal Analog/Digital
29 Control Signal
30
31
32 VALVE POSITION INDICATION
33 Local Valve Position Indication
34 Continuous Indication
35 Position Switches
36 Position Switch Rating
37 Lamp Drivers
38 Valve Opening
39 Actuator Fault
40 Incomplete Travel
41
42
43
44
45
Revision No./Date
Prepared by/Date
Authorised by/Date
Purpose
(C) 1999 NATIONAL OIL CORPORATION. The information on this sheet may be used only for the purpose for which it is supplied by NOC.
K:\nocspecs\SPECIFICATIONS\j-series\j-09\DJ0901R0.xls Sheet3