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Materials System Specification

34-SAMSS-634 Local ZV Control Systems Instrumentation Standards Committee Members


Juaib, Mohammed Khalifah, Chairman Tuin, Rienk, Vice Chairman Chetia, Manoj Dakhil, Tareq Khalil Ell, Steven Tal Fadley, Gary Lowell Faer Al Sharif, Hisham Mohammed Falkenberg, Anton Raymond Grainger, John Francis Harbi, Ahmed Saad Jumah, Yousif Ahmed Khalifa, Ali Hussain Mahmood, Balal Mathew, Vinod Qaffas, Saleh Abdal Wahab Qarni, Mahdi Ali Sahan, Fawaz Adnan Saleem, Hesham Salem Trembley, Robert James

10 March 2009

Saudi Aramco DeskTop Standards


Table of Contents 1 2 3 4 5 6 7 8 9 10 11 12 Scope............................................................. 2 Conflicts and Deviations................................. 2 References..................................................... 2 Environmental Conditions.............................. 3 General Requirements................................... 5 Smart ZV Local Control System..................... 6 Local ZV Shutdown Cabinets....................... 11 Installation.................................................... 11 Electrical Installation..................................... 11 Nameplates.................................................. 12 Drawings...................................................... 12 Other Miscellaneous Requirements............. 12

Previous Issue: 21 December 2005 Next Planned Update: 1 January 2011 Revised paragraphs are indicated in the right margin Primary contact: Flanders, Patrick Scott on 966-3-8746413
CopyrightSaudi Aramco 2009. All rights reserved.

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Document Responsibility: Instrumentation Issue Date: 10 March 2009 Next Planned Update: 1 January 2011

34-SAMSS-634 Local ZV Control Systems

Scope This specification covers the Saudi Aramco requirements for local Emergency Isolation Valve (ZV) control systems. Included are requirements for the ESD system input/output channels, the local control panel (LCP), and the smart valve controller that make up each Smart ZV. The Smart ZV assembly provides local control and testing functionality for spring return and double acting pneumatic valve actuators. Functional requirements are clarified including the "partial stroke" feature provided for on-line testing of ZV's. Alternative designs shall only be used when pre-approved by the Manager, Process and Control Systems Department.
Commentary Notes: All Emergency Isolation Valves (ZV's) are required to be designed and installed such that they can be functionally tested while on-line (in-service). Functional testing may take the form of a full-stroke test or a "partial stroke" test. "Partial stroke" testing provides a way to verify ZV performance when functional testing is required while the ZV is on-line. "Partial Stroke" testing is not intended to take the place of full-stroke ZV functional tests. Rather, "partial stroke" testing should be performed to meet the required functional test interval (e.g., quarterly) between scheduled unit shut downs when full stroke testing can be performed.

Conflicts and Deviations 2.1 Any conflicts between this specification and other applicable Saudi Aramco Materials System Specifications (SAMSSs), Engineering Standards (SAESs), Engineering Procedures (SAEPs), Standard Drawings (SASDs) or industry standards, codes, and forms shall be resolved in writing by the Company or Buyer Representative through the Manager, Process & Control Systems Department of Saudi Aramco, Dhahran. Direct all requests to deviate from this specification in writing to the Company or Buyer Representative, who shall follow internal company procedure SAEP-302 and forward such requests to the Manager, Process & Control Systems Department of Saudi Aramco, Dhahran.

2.2

References The following Supplementary Specifications are referenced by and form a part of this specification. 3.1 Saudi Aramco References Saudi Aramco Engineering Procedure SAEP-302 Instructions for Obtaining a Waiver of a
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Document Responsibility: Instrumentation Issue Date: 10 March 2009 Next Planned Update: 1 January 2011

34-SAMSS-634 Local ZV Control Systems

Mandatory Saudi Aramco Engineering Requirement Saudi Aramco Library Drawings DA-950065 DB-950106 DB-950129 Local Shut-Down Cabinet (Limited Travel Test) Smart ZV Local Shut-Down Cabinet (Conventional)

Saudi Aramco Inspection Requirements Form 175-343100 Instrument Control Cabinets Outdoor

Saudi Aramco Forms and Data Sheets Form NMR-7907 Form 8020-634-ENG 3.2 Industry Codes and Standards The cabinet shall be designed and fabricated in conformance with the latest requirements of the following: The International Society for Measurement and Control ISA ISA RP60.6 Nameplates, Labels and Tags for Control Centers Non Material Requirements for Instrumentation (General) Local ZV Controls

National Electrical Manufacturers Association NEMA 250 NEMA ICS 6 Enclosures for Electrical Equipment (1000 Volts Maximum) Enclosures for Industrial Controls and Systems

National Fire Protection Association NFPA 70 National Electrical Code

When listing is available, all equipment and materials of construction shall be listed for the intended service by Underwriters Laboratories, Inc. (UL), Factory Mutual Research Corporation (FM), or other recognized testing laboratory. 4 Environmental Conditions 4.1 Temperature ZV cabinet instruments and control components shall operate continuously
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Document Responsibility: Instrumentation Issue Date: 10 March 2009 Next Planned Update: 1 January 2011

34-SAMSS-634 Local ZV Control Systems

under the following ambient air temperatures without any degradation of the manufacturer's guaranteed performance.
Outdoor Sheltered Maximum Minimum
Notes: 1) 2) "Sheltered" refers to permanent, ventilated enclosures or buildings, or permanently fixed sunshades with a top and three sides. For instruments which dissipate internal heat and are installed in custom engineered enclosures (e.g., enclosures not included in the original manufacturer's temperature certification), an additional 15C shall be added to the above maximum temperatures. An example, for "indoor air conditioned" installation, the equipment must perform at 35 + 15 = 50C. Similarly, for the "outdoor unsheltered" case, the equipment shall be designed for a maximum operating temperature of 65 + 15 = 80C. For the outdoor installations only, the designer can take credit for forced or passive cooling to eliminate or reduce the 15C heat rise. For example, if vortex coolers are used, the heat removal capacity of the coolers may be subtracted from the generated heat. No more than 15C reduction in temperature will be given as credit. The designer shall substantiate his claim by providing the support data and calculations.
(1)(2)(3)

Outdoor Unsheltered 65C (149F) 0C (32F)

(2)(3)

55C (131F) 0C (32F)

3)

4.2

Humidity Design basis shall be 5% to 95% relative humidity (non-condensing).

4.3

Contaminants The instrument manufacturer shall ensure that all equipment is designed to withstand the following air quality requirements.
Commentary Note: Air-borne dust concentrations and contaminant levels are used in mechanical equipment design, when sizing air filters and as a measure of potential dust ingress.

4.3.1

Dust Concentration Usual airborne dust concentration is 1 mg/m. During sandstorms, dust concentrations may reach 500 mg/m. Particle sizes are as follows: 95% of all particles are less than 20 micrometers 50% of all particles are less than 1.5 micrometers Elements present in dust include compounds of calcium, silicon, magnesium, aluminum, potassium, chlorides and sodium. When wetted

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Document Responsibility: Instrumentation Issue Date: 10 March 2009 Next Planned Update: 1 January 2011

34-SAMSS-634 Local ZV Control Systems

(high humidity conditions) these compounds function as electrolytes and can result in severe corrosion. Other pollutants present in the atmosphere under the most extreme conditions are: H2S Hydrocarbon SO2 CO NOx O3 4.3.2 Wind-borne Sea Water Spray Equipment installed offshore or nearshore (i.e., within 0.5 km from shoreline), shall be suited for the harsh environment (NEMA 4X enclosure, 316 SST externals, hermitically sealed, etc.). 5 General Requirements 5.1 Local ZV Control Each pneumatically operated ZV shall be provided with local controls that permit the ZV to be operated in the event of an emergency and to be returned to the normal operating position locally when the emergency conditions have returned to normal, trip initiators are healthy, and the logic system has been reset (ready-to-reset light energized). 5.2 Local ZV Reset Resetting the ESD system logic via the remote pushbutton in the control room shall not cause the associated ZV's to automatically return to their normal operating position. Manual local operator intervention is required to verify conditions in the field prior to resetting a ZV, following a trip. In high-pressure applications (GOSP inlet, etc.), the ESD system shall prevent the ZV from opening until the pressure differential across the valve has reached a safe level (via differential pressure ESD input). 20 ppm (Vol/Vol) 150 ppm (Vol/Vol) 10 ppm (Vol/Vol) 100 ppm (Vol/Vol) 5 ppm (Vol/Vol) 1 ppm (Vol/Vol)

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Document Responsibility: Instrumentation Issue Date: 10 March 2009 Next Planned Update: 1 January 2011

34-SAMSS-634 Local ZV Control Systems

Smart ZV Local Control System The Smart ZV system shall be comprised of a Local Control Panel (LCP), a smart valve positioner, solenoid valves, an ESD HART handheld communicator (or equal computer based configuration), and associated ESD I/O as outlined in section 6.6 and shown in Library Drawing DB-950106, Sheets 1 and 2. In addition, when requested by the proponent, HART signal splitters/multiplexers within the ESD system marshalling cabinets shall be provided to facilitate integration with vendor specific valve diagnostic software. 6.1 Local Control Panel (Smart ZV) Each Smart ZV shall be equipped with a local control panel (LCP) to permit the ZV to be operated locally in the event of an emergency, to be returned to the normal operating position when the trip initiators are healthy, and to facilitate functional testing of the ZV. The LCP may be Hardwired or Integrated as described below. 6.1.1 Smart ZV LCP Pushbuttons A Smart ZV LCP shall include three pushbuttons: 1) valve close, 2) valve open, and 3) test. The local push buttons shall be shrouded to prevent unintended actuation.
Commentary Note: The Smart ZV LCP pushbuttons are closely integrated with ESD system logic and the control elements mounted on the valve (smart valve positioner, solenoid valves, and limit switches).

1)

Valve Close Push-button A momentary contact pushbutton to close the valve shall be provided. A Hardwired LCP local valve close push button contacts shall open on actuation and shall be hardwired as a discrete input to the ESD system. The ESD logic and outputs shall drive the valve to the closed position when the local close pushbutton is activated at the LCP. Alternatively, when a Smart ZV with integrated LCP is specified, the LCP pushbuttons and lights will be monitored and controlled by the associated ZV smart valve controller (DVC with LCP100 or equal).

2)

Valve Open Push-button A momentary contact pushbutton to open the valve shall be
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Document Responsibility: Instrumentation Issue Date: 10 March 2009 Next Planned Update: 1 January 2011

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provided. A Hardwired local valve open pushbutton contacts shall close on actuation and shall be hardwired as a discrete input to the ESD system. The ESD logic and outputs shall drive the valve to the open position when the local open pushbutton is activated at the LCP. Alternatively, when a Smart ZV with integrated LCP is specified, the LCP pushbuttons and lights will be monitored and controlled by the associated ZV smart valve controller (DVC with LCP100 or equal). 3) Test Push-button A momentary contact pushbutton to initiate a partial-stroke test shall be provided. The local test pushbutton shall close on actuation and shall be hardwired from the LCP directly to the smart valve positioner (shall initiate the user defined partial stroke test residing in memory within the smart valve positioner). Alternatively, when a Smart ZV with integrated LCP is specified, the LCP pushbuttons and lights will be monitored and controlled by the associated ZV smart valve controller (DVC with LCP100 or equal). 6.1.2 Smart ZV LCP Indication Lamps The LCP shall include a ready-to-reset indication lamp to provide local indication when the ZV may be returned to the normal operating position following an ESD system trip. The ready-to-reset lamp shall be powered via a discrete output from the ESD system. Alternatively, when a Smart ZV with integrated LCP is specified, the LCP pushbuttons and lights will be monitored and controlled by the associated ZV smart valve controller (DVC with LCP100 or equal).
Commentary Note: Ready-to-Reset light: The lamp shall illuminate when all relevant ESD inputs are in the healthy condition and the logic system has been reset. The lamp shall extinguish when the valve moves from the fail-safe position.

When specified on Form 8020-634-ENG, local ZV open and closed valve position indication lamps shall be included within the LCP. a) b) LED type lights shall be provided (e.g., Stahl 8010/2-01 or equal). Colors used shall be Open Green, Closed Red, and Ready to Reset Amber.

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Document Responsibility: Instrumentation Issue Date: 10 March 2009 Next Planned Update: 1 January 2011

34-SAMSS-634 Local ZV Control Systems

6.1.3

Local Control Panel Terminations Terminal strips within the ZV LCP shall be adequately sized to allow easy access to the terminations (hinged swing-out space saver, double or triple gang type terminations are not allowed). The LCP enclosure shall be adequately sized to allow easy termination of external cables and include space for the lay of conductors.

6.1.4

Local Control Panel Vent/Drain A combination vent/drain fitting shall be provided on each LCP.

6.2

Smart Valve Positioner A ZV will be made smart by the introduction of a smart electro-pneumatic valve positioner as part of the valve assembly (Fisher Rosemount DVC 6000 or approved equal with external solenoid valve). The smart valve positioner shall be mounted on the ZV actuator to facilitate online, partial stroke (limited travel) testing, full-stroke out-of-service testing, and self-health monitoring via the smart valve positioner diagnostic software. The positioner shall be installed in series with solenoid valve(s). The smart valve positioner shall communicate with the ESD system via a dedicated 4-20 ma DC/HART hybrid ESD output channel. In the event of a trip, the solenoid valve will change state (de-energize) and the positioner signal (4-20 mA DC) shall be driven to the user defined value.

6.3

Smart Valve Positioner Mounting Kit Each Smart ZV positioner shall be supplied with an actuator mounting kit designed specifically for use on the intended actuator. Each mounting kit shall include provisions for valve position limit switches (valve open and valve closed). Hermetically sealed or totally encapsulated, mechanical switch or proximity sensor position switches with contacts rated for the required load shall be specified.

6.4

On-line Testing Each Smart ZV shall be equipped with a LCP as described above in Section 6.1. In addition to the open and close pushbuttons, a valve test pushbutton shall be included to initiate the predefined partial stroke test (residing in memory within the smart valve positioner).

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Document Responsibility: Instrumentation Issue Date: 10 March 2009 Next Planned Update: 1 January 2011

34-SAMSS-634 Local ZV Control Systems

In addition to the LCP test pushbutton, on-line testing of a Smart ZV may be initiated via HART protocol using a laptop computer with vendor specified valve testing and diagnostic software. Remote partial-stroke testing of ZVs may also be accomplished by using HART multiplexed external output termination modules or assemblies with an associated ZV maintenance workstation.
Commentary Note: The selection and loading of the Multiplexers and HART filters supplied with ESD marshalling terminations to integrate the hybrid HART analog 4-20 mA signal to the smart valve postioner, shall be guaranteed by the ESD vendor for proper operation with the ESD analog I/O card and the smart valve positioner.

6.5

Solenoid Valve(s) The solenoid valves utilized with Smart ZV's shall be electro-pneumatic direct operating or external pilot type (capable of operating without applied differential pressure). They shall be used to pressurize/vent the actuator in response to an ESD trip in a fail-safe arrangement with the smart valve positioner. All solenoid valves shall be specified with Viton internals. Reference Library Drawing DB-950106, Sheet 1 and 2 for the Emerson/Fisher DVC based Smart ZV architecture.

6.6

ESD I/O The Smart ZV is an integration of local controls mounted on the ZV (smart valve positioner, solenoid valves, limit switches, etc.), the LCP, and ESD system I/O and logic. The ESD I/O required to integrate a Smart ZV is summarized in the table below. Alternatively, the Smart ZV with integrated LCP (Emerson DVC 6000 with LCP100 or equal) is acceptable provided the distance between the LCP and the associated ZV Smart Valve Controller is within vendor specified limits. External 24 VDC power supply is required for each LCP specified as part of a Smart ZV with integrated LCP. Smart ZV ESD I/O Requirements

ESD Inputs / Outputs Discrete Input - 1 Discrete Input - 2 Discrete Input 3 ESD I/O not required for Integrated LCP.

Type Limit Switch - ZV valve open Limit Switch - ZV valve closed Pushbutton ZV valve open

Description Used within ESD logic to monitor ZV position. Used within ESD logic to monitor ZV position. This pushbutton is located on the LCP.

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Document Responsibility: Instrumentation Issue Date: 10 March 2009 Next Planned Update: 1 January 2011 ESD Inputs / Outputs Discrete Input 4 ESD I/O not required for Integrated LCP. Type Pushbutton ZV valve close

34-SAMSS-634 Local ZV Control Systems Description This pushbutton is located on the LCP. Provides high valve flow coefficient (Cv) to meet ZV closure time requirement and provides the primary ESD function. Note: The smart valve positioner will also move the valve to the fail safe position should the solenoid fail to operate during an ESD trip. On double acting ZV's where two solenoids are used, and they are both controlled by this one (1) ESD output. This Indication Lamp is located in the local control panel (LCP). Provides local indication at the ZV when the ESD has been reset in the control room and all permissives are met. Only then may the ZV be safely returned to the "normal operating position." This indication Lamp is located in the local control panel (LCP). Provides local indication at the ZV when the valve is fully open (via hardwired limit switch to ESD discrete input). This indication Lamp is located in the local control panel (LCP). Provides local indication at the ZV when the valve is fully closed (via hardwired limit switch to ESD discrete input). Analog output (4-20 mA) to Smart Valve Positioner. This signal provides a backup means to drive the ZV to the fail-safe position should the primary ESD device (solenoid valve) fail to function. Multiplexed ESD I/O is required to utilize HART diagnostic information available to a ValvLink workstation.

Discrete Output - 1

Solenoid Valve(s)

Discrete Output 2 ESD I/O not required for Integrated LCP.

Indication Lamp - Ready to Reset (Amber color)

Discrete Output 3 ESD I/O not required for Integrated LCP.

Indication Lamp Valve Open (Green color)

Discrete Output 3 ESD I/O not required for Integrated LCP.

Indication Lamp Valve Closed (Red color)

Analog Output 1

ZV positioner

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Document Responsibility: Instrumentation Issue Date: 10 March 2009 Next Planned Update: 1 January 2011

34-SAMSS-634 Local ZV Control Systems

Field 'Test' Pushbutton Local Control Panel ZV "Test" Pushbutton ESD I/O not required for Integrated LCP.

Type

Description LCP ZV Test pushbutton is hardwired directly to the smart valve positioner. Local Test pushbutton initiates the predefined "partial stroke" test. The smart valve positioner saves the most recent valve test signature.

Pushbutton Initiate Partial Stroke Test

Local ZV Shutdown Cabinets When Smart ZV local controls are not suited to the application (e.g., gas operated valves), local ZV shutdown cabinets shall meet the design requirements of this specification, Saudi Aramco Form 8020-634-ENG, and the applicable Saudi Aramco Library Drawing (DB-950129 or DA-950065). Alternative designs shall only be used when pre-approved by the Manager, Process and Control Systems Department.

Installation 8.1 Tubing shall be seamless, 316 stainless steel. The minimum tube size shall be inch (12.7 mm) O.D. and have a minimum wall thickness of 0.03 inch (0.75 mm).
Exception: Non-flowing pneumatic tubing such as pilot operated solenoid valve impulse lines may be inch (6.35 mm) O.D.

8.2 8.3 8.4

Fittings shall be 316 stainless steel compression type Swagelok, Parker, or equal. Threaded connections shall be sealed using paste. Tubing shall be bent using a tubing bender, reamed and internally cleaned prior to installation. Pressure gauges indicating incoming supply pressure and operating pressure to the valve actuator (open and closed side of dual acting and open side of single acting actuators) shall be provided in SI or English units consistent with the unit convention used in the intended plant location.

Electrical Installation 9.1 All materials and equipment shall meet NFPA 70, National Electrical Code requirements for the intended hazardous areas.

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34-SAMSS-634 Local ZV Control Systems

9.2

All components (solenoid valves, limit switches, indication lights, etc., shall be certified for use in the intended hazardous area by an approved testing agency without the need for any additional external protection. Both EEx and AEx Certified devices are acceptable. Electrical wiring and installation shall conform to the requirements of the NFPA 70, National Electrical Code, latest edition. Wiring internal to the LCP and local ZV shutdown cabinet shall be 18 AWG minimum. Wire ends shall connect to polyamide terminals within the cabinet. Terminal make shall be Klippon, Weidmuller, or equal.

9.3

9.4

10

Nameplates 10.1 10.2 Nameplates shall follow ISA RP60.6 guidelines. All instruments mounted inside local ZV shutdown cabinets or associated with Smart ZV systems, shall be identified by a nameplate including the tag number and service description. The nameplates shall be attached with stainless steel screws or stainless steel wire. Nameplates shall be made from laminated plastic white-black-white (information engraved into the black core).

10.3 10.4

11

Drawings Vendor shall supply a drawing with complete details of the Smart ZV or cabinet construction and dimensions, including a detailed bill of materials, description of operation, and termination electrical diagram.

12

Other Miscellaneous Requirements 12.1 Local ZV Shutdown Cabinet Operating Instructions Laminated, brief step-by-step operating instructions shall be attached to the inside of the cabinet door. The operating instructions shall be printed in large easy to read font (black letters on white background) suitable for reference in the field during cabinet operation. 12.2 Nonmaterial Requirements The supplier shall provide nonmaterial items as listed on Form NMR-7907.

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34-SAMSS-634 Local ZV Control Systems

12.3

Inspection Items manufactured to this Specification are subject to the minimum Inspection requirements as specified in Saudi Aramco Inspection Requirements Form 175-343100.

12.4

Each Smart ZV shall be assembled, configured, and tested in the factory prior to shipment (valve, actuator, solenoid valves, smart valve positioner, and local control panel). A full-stroke valve signature shall be taken, saved on disc, and shipped with the assembled Smart ZV. The user specified partial stroke test shall be configured within the smart valve positioner in the factory and tested using the local control panel pushbutton prior to shipment. The vendor responsible for the assembled ZV shall provide a failure rate value for the complete final element (valve, actuator, and local controls) for use in safety integrity level verification calculations. Although third party safety certification or failure mode and analysis is preferred, the vendor may estimate the failure rate for the assembled ZV and controls based on proven-in-use historical data.
Commentary Note: The overall failure rate provided for the assembled ZV shall include the contribution of the individual control components (valve, actuator, smart valve positioner, solenoid valves, etc.). Data shall be provided to support the failure rates assigned to each component.

12.5

21 December 2005 10 March 2009

Revision Summary Revised the "Next Planned Update." Reaffirmed the contents of the document, and reissued with minor changes. Minor revision to include the Smart ZV with Integrated LCP technology.

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