Materials System Specification

34-SAMSS-634 10 March 2009

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

Saudi Aramco DeskTop Standards

Table of Contents

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

Previous Issue: 21 December 2005 Next Planned Update: 1 January 2011

Revised paragraphs are indicated in the right margin Page 1 of 13
Primary contact: Flanders, Patrick Scott on 966-3-8746413

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Instrumentation 34-SAMSS-634
Issue Date: 10 March 2009
Next Planned Update: 1 January 2011 Local ZV Control Systems

1 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.

2 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.
2.2 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.

3 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 34-SAMSS-634
Issue Date: 10 March 2009
Next Planned Update: 1 January 2011 Local ZV Control Systems

Mandatory Saudi Aramco Engineering

Requirement

Saudi Aramco Library Drawings

DA-950065 Local Shut-Down Cabinet (Limited Travel Test)
DB-950106 Smart ZV
DB-950129 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 Non Material Requirements for Instrumentation
(General)
Form 8020-634-ENG Local ZV Controls

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

National Electrical Manufacturers Association

NEMA 250 Enclosures for Electrical Equipment
(1000 Volts Maximum)
NEMA ICS 6 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 34-SAMSS-634
Issue Date: 10 March 2009
Next Planned Update: 1 January 2011 Local ZV Control Systems

under the following ambient air temperatures without any degradation of the
manufacturer's guaranteed performance.

(1)(2)(3) (2)(3)
Outdoor Sheltered Outdoor Unsheltered
Maximum 55°C (131°F) 65°C (149°F)
Minimum 0°C (32°F) 0°C (32°F)

Notes:
1) "Sheltered" refers to permanent, ventilated enclosures or buildings, or permanently fixed
sunshades with a top and three sides.
2) 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 15°C shall be added to the above maximum temperatures.
An example, for "indoor air conditioned" installation, the equipment must perform at
35 + 15 = 50°C. Similarly, for the "outdoor unsheltered" case, the equipment shall be
designed for a maximum operating temperature of 65 + 15 = 80°C.
3) For the outdoor installations only, the designer can take credit for forced or passive
cooling to eliminate or reduce the 15°C 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 15°C reduction in temperature will be given as credit. The designer
shall substantiate his claim by providing the support data and calculations.

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/m³. During sandstorms, dust

concentrations may reach 500 mg/m³. 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 34-SAMSS-634
Issue Date: 10 March 2009
Next Planned Update: 1 January 2011 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 20 ppm (Vol/Vol)
Hydrocarbon 150 ppm (Vol/Vol)
SO2 10 ppm (Vol/Vol)
CO 100 ppm (Vol/Vol)
NOx 5 ppm (Vol/Vol)
O3 1 ppm (Vol/Vol)

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).

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Document Responsibility: Instrumentation 34-SAMSS-634
Issue Date: 10 March 2009
Next Planned Update: 1 January 2011 Local ZV Control Systems

6 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 34-SAMSS-634
Issue Date: 10 March 2009
Next Planned Update: 1 January 2011 Local ZV Control Systems

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) LED type lights shall be provided (e.g., Stahl 8010/2-01 or equal).
b) Colors used shall be Open – Green, Closed – Red, and Ready to
Reset – Amber.

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Document Responsibility: Instrumentation 34-SAMSS-634
Issue Date: 10 March 2009
Next Planned Update: 1 January 2011 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 on-
line, 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 34-SAMSS-634
Issue Date: 10 March 2009
Next Planned Update: 1 January 2011 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 Type Description

Discrete Input - 1
Discrete Input - 2
Discrete Input – 3
ESD I/O not required for
Integrated LCP.
Limit Switch - ZV valve open
Limit Switch - ZV valve
closed
Pushbutton – ZV valve open
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.
Discrete Output - 1
Discrete Output – 2
ESD I/O not required for
Integrated LCP.
Discrete Output – 3
ESD I/O not required for
Integrated LCP.
Discrete Output – 3
ESD I/O not required for
Integrated LCP.
Analog Output – 1
Type
Pushbutton – ZV valve close
Solenoid Valve(s)
Indication Lamp - Ready to
Reset (Amber color)
Indication Lamp – Valve
Open (Green color)
Indication Lamp – Valve
Closed (Red color)
ZV positioner
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.
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Document Responsibility: Instrumentation 34-SAMSS-634
Issue Date: 10 March 2009
Next Planned Update: 1 January 2011 Local ZV Control Systems

Field 'Test' Pushbutton Type Description

Local Control Panel ZV
"Test" Pushbutton
ESD I/O not required for
Integrated LCP.
Pushbutton – Initiate Partial
Stroke Test
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.

7 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.

8 Installation

8.1 Tubing shall be seamless, 316 stainless steel. The minimum tube size shall be ½
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 ¼ inch (6.35 mm) O.D.

8.2 Fittings shall be 316 stainless steel compression type Swagelok, Parker, or
equal. Threaded connections shall be sealed using paste.

8.3 Tubing shall be bent using a tubing bender, reamed and internally cleaned prior
to installation.

8.4 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.

9 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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Document Responsibility: Instrumentation 34-SAMSS-634
Issue Date: 10 March 2009
Next Planned Update: 1 January 2011 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.

9.3 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.

9.4 Wire ends shall connect to polyamide terminals within the cabinet. Terminal
make shall be Klippon, Weidmuller, or equal.

10 Nameplates

10.1 Nameplates shall follow ISA RP60.6 guidelines.

10.2 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.

10.3 The nameplates shall be attached with stainless steel screws or stainless steel
wire.

10.4 Nameplates shall be made from laminated plastic white-black-white

(information engraved into the black core).

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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Document Responsibility: Instrumentation 34-SAMSS-634
Issue Date: 10 March 2009
Next Planned Update: 1 January 2011 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.

12.5 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.

Revision Summary
21 December 2005 Revised the "Next Planned Update." Reaffirmed the contents of the document, and
reissued with minor changes.
10 March 2009 Minor revision to include the Smart ZV with Integrated LCP technology.

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